A modern, turn-milling bar automatic is on average more than 10 times as productive as a previous-generation model from the same German manufacturer, says a leading lock producer.

A modern, turn-milling bar automatic from Traub is on average more than 10 times as productive as a previous-generation model from the same German manufacturer, says a leading British lock producer. It is well placed to judge, having replaced five lathes purchased in the mid-1990s - single- and twin-turret models, with and without driven tooling - with a new Traub TNK 36. Installed in July 2004 by UK agent, Geo Kingsbury, the German-built machine produces in a single shift the same number of lock cylinders that the five older machines turned out over two shifts and sometimes well into a third.

In addition, many of the components previously needed second operations, such as slot milling.

Anyone keen to compete more effectively, particularly with overseas manufacturers, will benefit from the significant cost savings that machines like the TNK 36 provide.

The high degree of automation takes away much of the advantage of low-wage economies, as the labour cost element of manufacture is reduced drastically.

This has been the lock manufacturer's experience.

Whereas six people were previously employed to operate the former production cell during each of two shifts, only two operators are now needed over a single shift, representing a 12-fold saving in wages.

So productive is the TNK 36 that lock cylinder production alone is not sufficient to occupy the machine, even for a single shift, despite 1.5 million locks being produced annually.

So other lock and padlock components have been added to the lathe's remit and there are plans to put on mortise and multi-lock components.

Currently, six variants of cylinder of 19, 24 and 36mm diameter in different lengths and styles are produced, plus additional components, in batches of 500- to 2,500-off.

In the former cylinder production process, the now-replaced Traub lathes turned and milled the components as far as the capability of each machine allowed.

Further operations were needed to complete the parts, involving manual handling onto milling, drilling and tapping machines.

Cycle time on one of the old lathes was two-and-a-half minutes on average, followed by one minute of secondary operations, plus handling time.

By contrast, cylinders are produced in one hit on the Traub TNK 36.

Each component requires 40s of machining, although one part comes off the machine every 20s - over 10 times faster than from the previous cell - by virtue of simultaneous cutting using the main and sub spindles.

Such comprehensive machining is enabled by a large number of tools, namely two in-line gang toolposts with five stations each (four of which are driven), one for front endworking and the other for reverse endworking; and a 12-station turret on which all stations are live.

Brass bar is fed through the main spindle from a Hydrabar full-length magazine.

Turning of the OD, facing, drilling and counterboring are all performed simultaneously, followed by drilling five pinholes, milling of a dovetail slot and part-off.

At the same time, the previous component, after having been picked up by the sub-spindle, undergoes machining of a back boss and has two holes drilled and tapped, followed by a chamfer turning operation to deburr.

A process capability of Cpk 1.66 was recorded during machine pass-off, while Cpk 1.33 is routinely achieved.

A spokesman for the manufacturer commented that the new Traub lathe is unbelievably flexible and can machine practically anything.

It means that the design department now has very few restrictions when working on new lock models.

Obtaining the maximum productivity from 'single-cycle' mill/turning applications on CNC sliding head automatic lathe was the theme set by NC Engineering at its 2005 Open House.

Obtaining the maximum productivity from 'single-cycle' mill/turning applications for CNC sliding head auto produced components up to 32mm diameter and fixed head mill/turn centres up to 42mm capacity, was the theme set by NC Engineering for its Open House staged at its Bushey, Watford, UK. showroom in October 2005. Joined by leading tooling specialist Sandvik Coromant, demonstrating a new range of tooling at the event, NC Engineering showed under power for the first time in the UK, the production advantages available from three new machine developments by Citizen.

The two new sliding head machines, the high precision and fast cycling RO7 employing linear drive technology and the latest M16-V which, like the larger capacity M32, now employs a second Y-axis to the turret as well as the tool slide, provides a massive leap in flexibility for setting and shortening cycle times.

From the fixed head stable of Citizen Boley, the new BE 42 also brings many of the advantages and common elements of world-leading sliding head technology from Citizen to fixed head machining for parts up to 42mm diameter, using the main and subspindle and its twin, driven tool turrets.

Talking productivity increases is one thing - proving and quantifying the benefits is another and here, NC Engineering and Sandvik Coromant have had extensive successes at Citizen users generating huge savings from joint application development.

A recent prime example was at Monument Tools of Hackbridge, Surrey, UK, where two new Citizen M32 CNC sliding head machines replaced fixed head lathes and milling machines creating savings up to a massive 60%.

In addition, lead times have been significantly reduced by combining up to five separate operations into one with NC Engineering and Sandvik Coromant developing a special polygon turning process resulting in the reduction in cost of cutting tool inserts from GBP 45 to just GBP 3.

Also by switching to thinner CoroCut 1.5mm wide parting inserts consumption of steel bar has been reduced by a 1000m on a particular job.

Indeed, at the Open House, Sandvik Coromant demonstrated its new CoroCut MB (minibar) boring concept for grooving, turning and threading holes over 10mm diameter.

Also presented was CoroCut XS (extra small) for smaller bores down to 1mm diameter.

A new range of Delta C drills between 0.3 and 1.4mm.

Alongside the new citizen machines were the latest K-Series CNC sliding head auto in 12mm and 16mm capacities and the all new Citizen L20.

The first UK installation of two L20 machines in the UK at Unicut Precision have already enabled floor to floor times to be cut by up to 30% due to faster processing and dramatic reductions in idle times.

Updated, compact CNC six-spindle lathe has highly dynamic drive for consistent surface finishes, high cutting speeds, stepless spindle speeds and servo controlled C-axis milling.

The new updated version of our latest full CNC multi-spindle lathe will be shown at this year's EMO exhibition at Hannover, 14.09.2005 to 21.09.2005. The SC26 marks the start of an evolutionary development in multi-spindle turning technology. What distinguishes its design is the consistent application of cutting edge technologies that lead to a considerable increase in performance and flexibility.

This six spindle automatic is of a remarkably compact construction, facilitated by the application of new production methods and the realisation of innovative solutions.

New dimensions have been reached with respect to machining area accessibility, ease of setting and operator friendliness.

The machine also has an extraordinary chip capacity.

It requires an efficient, highly dynamic drive concept to satisfy the extreme demands for consistent surface finishes, highest precision, high cutting speeds also on small workpiece diameters, infinitely variable spindle speeds and servo controlled C-axis milling and cross machining.

These requirements have been fulfilled with the introduction of work spindles that are designed as individually controlled motor spindles.

All work spindles can be individually stopped, positioned at an angle and used for C-axis applications.

The motor spindles are equipped with an integral cooling system that makes use of the existing, already tempered hydraulic oil in the machine.

This eliminates any negative effect the environment might otherwise have on the machining process.

The SC26 is fitted with standard CNC components and a control system based on the Sinumerik 840D.

CNC programs are generated for each spindle position separately which can be achieved without any particular programming aids, using anything from a simple editor to the most intelligent project workstations for CNC programming in ISO code.

We would be happy to welcome all UK and Irish companies onto our stand at Hannover or to our factory in Cologne and demonstrate not only the SC26 but our complete range of multi-spindle automatic lathes.

After researching the market, a sliding-head, mill-turn automatic was chosen due to the supplier's reputation for good service back-up, which is essential for users that are new to a technology.

In 2001, the turned parts division of subcontractor, MSP, started to sell some of the 27 cam-type multi-spindle automatics it had used since 1969 and replace them with computer-controlled turning machines. It was in response to the loss of long runs of 100,000 and above to countries such as China and India. By this summer, four CNC sliding-headstock turning machines from Star and five fixed-head lathes had been installed at the Birmingham site and the number of multis had shrunk by a third to 18.

Commented MSP's managing director, Bob Taylor, 'The split between CNC and multi work here is now around 40:60 and I can see the latter reducing to 20% in the next two to three years.

You need a run of at least 20,000 parts to justify setting up one of the multis, or a minimum of 100 hours work, whereas the Stars are economic for smaller quantities.

We do, however, try to secure orders for 2,000 and upwards if we can, which we supply to customers in batches of typically 200 to meet their just-in-time delivery requirements.' Based on this versatility, BTMA member MSP positions itself as a 'one-stop-shop' for precision turned parts, with the emphasis on quality, prompt delivery and customer service.

It has 40 live customers at any one time, the automotive industry accounting for up to 40% of turnover.

Exotic alloys and hard stainless steels are frequently machined on the Stars, as their robust build allows such materials to be processed to high accuracy.

Many subcontractors try to avoid this type of work, so it tends to be easier to acquire and can be of higher added value.

Additionally, the growing medical sector requires these types of materials to be machined, presenting a further business opportunity.

Taylor advised that they work to tolerances of the order of +/-0.05mm on most days.

He went on to describe how MSP came to acquire its first sliding-headstock lathe - a Star SV-32 - in October 2003.

An automotive customer was regularly taking quantities of large diameter components which were being machined on the CNC fixed-head lathes.

Part of the contract entailed machining a smaller component in two parts that were subsequently brazed together.

However, problems with the final assembly led the customer to ask MSP to redesign the component and make it in one piece, the shape of which dictated the purchase of a slider and also a bending machine.

After researching the market, the Star lathe was chosen due to the supplier's reputation for good service back-up, which Taylor pointed out is essential for users that are new to a technology.

Despite the subcontractor's lack of experience in sliding-headstock mill-turning, MSP was able to complete the redesign and, with Star's assistance, manufacture the first batch of components in five days from the first discussion with the customer, which suitably impressed them.

On the back of this success, an entry-level Star SB-16 was installed one month after the SV-32, followed by an SR-20RII and an SV-32JII in 2004 and 2005 respectively.

'There will be a place for some multis here for the foreseeable future,' stressed Taylor, 'Because some industries continue to place orders for larger batches on UK suppliers.

A case in point is the gas sector, which requires very high precision parts to avoid leakage in domestic meters, for example.

Suppliers to the gas industry are very nervous of placing work abroad in case the quality of parts is sub-standard, so they tend to stay with European subcontractors just to keep on the safe side.

'A similar safety-first approach is practiced by the offshore and aerospace industries.' As a postscript, Taylor advised that modern CNC lathes such as the Stars have a further significant advantage over multis in that the latter require highly skilled setter/operators whereas the former are relatively straightforward for semi-skilled staff to set up and program.

Established in 1976 as a manufacturer of counterbore and countersink tooling, Robert Charles Cutting Tools of Southampton has updated its shopfloor equipment.

Established in 1976 as a manufacturer of counterbore and countersink tooling, Robert Charles cutting tools of Southampton has updated its shopfloor equipment. The updating of machine tools comes as part of the company's plans to meet the growing demands for specialist tooling in Europe and the growth potential of the US market. To help Robert Charles Cutting Tools with its global assault, the company has purchased Anca grinders and a Tornos Deco 26a sliding head turning centre.

Robert Charles cutting tool managing director, Robin Urry commented: 'Demand for our products was on the increase as was the variety of products and with aging machines we were finding it difficult to react to the needs of the market.

We knew it was time to invest in new technology and our production supervisor set about finding a suitable machine tool capable of producing parts in one-hit to reduce or eliminate second operations.' Production supervisor Mark Angel added: 'We did feasibility tests with all the leading sliding head manufacturers and Tornos came out top by a country mile.

We machine M35 high speed steel in average batch sizes of 500 to 1,000 and that requires a rigid machine with powerful driven tooling - the Tornos was the only machine that could meet our needs.' The company purchased the Tornos Deco 26a in 2003 and since its introduction the company hasn't looked back.

The Deco 26a increased productivity dramatically by turning parts on the main spindle, whilst simultaneously machining the back end of a part on the sub-spindle.

The previous turning centres produced blanks and then the company would conduct manual second operations such as milling and drilling before heat treatment and grinding.

The Deco has completely eradicated most manual milling and drilling operations with its power driven tooling.

The introduction of the Deco has enabled Robert Charles to increase its productivity and redeploy a number of employees from the turning section to alternative tasks.

This has reduced labour costs for turning considerably.

With regards to productivity, one product range has seen cycle time fall by 70 per cent.

The job previously took three minutes to produce, the Deco cut that time to 40 seconds.

'The next step is to introduce sensors to enable the company to run complete lights out operation.

With the current set-up, confidence in tooling not to fail and, thereby, produce scrap has been an issue and the addition of sensors will enable us to overcome the scrap problem and move on to a complete lights out operation,' continued Urry.

The Deco 26a has enabled the company to cope with the increasing global demands for its products.

One particular cutting tool that required three flats for a European customer was outside the company's production capabilities.

The ability of the Deco with its driven tooling has since enabled Robert Charles Engineering to meet the demands of what is now one of the company's largest customers.

Accuracy of components has also improved since the introduction of the Tornos Deco.

The machine has eliminated second operations on many parts and has improved repeatability, accuracy and reduced the potential for human error.

The parts are now produced so accurately that grinding operations have also been considerably reduced.

Urry said: 'I am delighted with the machine.

It has done everything we wanted and so much more.

We have improvements to productivity and capability, thus improving our position in our markets.

Tornos have provided us with an excellent product combined with great customer support and the combination has created an excellent working relationship between us.'

A Star Micronics GB system for turning, thread cutting, milling and gun-drilling titanium alloy tips and transducers for ultrasonic aspirators has proved successful for Integra Neuro Sciences.

A Star Micronics GB system for turning, thread cutting, milling and gun-drilling titanium alloy tips and transducers for ultrasonic aspirators has proved successful for the Andover factory of US-owned Integra Neuro Sciences. The tips, used in the treatment of brain tumours, are now produced 26 per cent faster, despite requiring a fine, 80:1 length-to-diameter hole drilled down the centre. The machine package is based on a Star SV-20 sliding-headstock, multi-axis, mill-turning centre fitted with a JBS guide bush that is able to compensate for variability in the diameter of the bar, which is fed by an FMB Turbo magazine.

Star Micronics GB, as well as being a subsidiary of its similarly named lathe manufacturing parent company in Japan, is also sole UK agent for the German suppliers, FMB and JBS.

Also fitted to the machine are a high-pressure (2,000psi) through-tool, neat oil coolant delivery system, automatic fire suppression and a range of tooling that best suits the various cutting operations.

Ceratizit inserts are used for profile turning and threading, Iscar Multi-Master tooling with modified chamfers have been chosen for milling hexagon flats, whilst solid carbide Botek gun drills are sourced through Mollart.

Completing the total manufacturing system supplied by Star were a suite of programs for machining tips and transducers to be used in Integra's new aspirator range, operator training and service back-up, including telephone help desk support from the supplier's Melbourne headquarters.

Commented Rob Sellwood, machine shop manager at the Inegra Andover factory: 'We used to produce 800 to 1,000 disposable titanium tips per month in a one-hit cycle averaging 15 minutes on an old and somewhat unreliable sliding-headstock lathe from another manufacturer.

The average cycle time has been reduced to 11 minutes on the Star lathe, representing a 26 per cent saving.' Key to achieving such a significant productivity increase is the capability of the sub spindle on the Star, which has led to the cutting cycles being balanced accurately between the two spindles.

Gun-drilling of Integra's component families is exacting, as exemplified by the two parts on which Star was asked to carry out time studies during three days of capability trials under production conditions at Melbourne.

The 120mm long tip was machined from 12.7mm diameter, 2TA11 titanium alloy bar and required a 1.5mm diameter gun-drilled through-hole down the centre, representing a length to diameter ratio of 80 to one.

In the case of the 144mm long transducer, a 2.7mm hole was needed down the 16mm diameter bar, equating to a length to diameter ratio of the 53 to one.

A very accurate result is achieved.

For example, drawing tolerance for concentricity at the tip end is 0.1mm, whereas less than 10microns is routinely held.

A tolerance of 0.3mm for concentricity is required at the back end, where the tip screws on to the transducer, yet half that figure is held.

Turned profile tolerance is +/- 50microns on the drawing, while +/- 10microns to 20microns is the norm in practice.

Moreover, they are achieved from a cold start in the morning through to the end of the single, eight-hour shift.

Integra does not rotate the gun drill on the Star, relying instead on a rotating component (bar) and a static drill.

The need for a guide bush is avoided by first drilling a pilot hole to a depth of three times diameter in to the bar end using a carbide twist drill.

The gun drill is programmed to advance in to this hole prior to the high-pressure coolant being switched on, as otherwise the tip would deflect during the delicate manoeuvre.

Gun-drilling to 13.6 metres is achieved between regrinds, substantially better than the 10 metres quoted by the supplier said Star.

According to Star, the JBS compensating guide bush has brought significant benefits to Integra.

Using the company's original sliding-headstock lathe, it was necessary when titanium bars were delivered, to measure the diameter of each along its length and segregate them in to different batches, such is the dimensional variability of the centreless-ground stock.

Even so, from five per cent to 10 per cent of components machined by Integra had to be scrapped, wasting machine time and expensive stock.

Now, with the JBS system, pneumatically operated grippers move in and out, compensating continuously for variations in bar diameter as it is fed through the guide bush, resulting in zero scrap.

Other systems on the market are adjustable, but once set, the bush is fixed and cannot self-adjust to suit the varying bar diameter.

Latest mechanical engineering, control system development and operating software improvements have reduced idle time by 40% on a CNC sliding head automatic lathe.

An average of 40% of the time lost in a CNC machining cycle time due to data processing, idle time and non-cutting movements can be saved through the latest mechanical engineering, control system development and operating software improvements created by Citizen for its latest L20VIII CNC sliding head auto. The new seventh generation of the highly successful L-Series machine will create new levels of savings, productivity and machine utilisation for producing mill/turn components up to 20mm diameter. Available through NC Engineering of Watford, the Citizen L20 VIII has undergone extensive test cycles against the previous generation machine using the same program and tooling.

In a 83s machining cycle, for instance, of which a quarter was attributed to non-cutting, this lost time was reduced to 69.5s a massive 63% saving.

Another 250s machining cycle, for instance, which previously included almost 24s of non-cutting time for data processing, positioning, acceleration and manipulation, this was reduced to just 7.9s, a saving of almost 67s and a third part with a 53.9s cycle involving 17s of idle time was reduced by 39% to just 10.5s.

The machine, with a capacity of 20mm diameter by 200mm machining length enables a variety of tool layouts to be selected to service the main 3.7kW, 10,000 rev/min spindle and 1.5kW, 8.000 rev/min subspindle according to the priority required for cross-machining, end face features or turning cycles.

When cross-machining is the priority, up to 18 tools can be mounted on cross toolholders which include five turning, seven rotary and six drilling tools.

The three cross toolholders may also be used for end face drilling spindles by swivelling the unit through 90 degrees.

When there is a higher demand for end face machining up to 21 tools can be mounted, including five turning tools, 10 rotary and six drilling tools and when inside diameter turning cycles predominate, a toolholder can be added to the driven tool mounting to provide three additional drilling and boring positions.

With rapid traverse rates increased from 20m/min to 32m/min, acceleration rates improved by a factor of 1.6 on all axes and the ability to overlap the exiting of one tool with entry into the cut of the next, not only does this contribute to shorter cycle times, but reduces any likelihood of vibration.

Vibration is also controlled by the introduction by Citizen of 'shockless' acceleration/deceleration curves.

These are a feature of the new smaller but higher performance servomotors which now provide up to 30% higher torque.

Driven tools are powered by 1kW, 4.500 rev/min motors enabling holes to be drilled up to 8mm diameter and tapped up to M6.

By specifying the long part adapter option, shafts between 80mm and 600mm in length can be processed and unloaded automatically out to the side of the machine.

There is also an option of a parts conveyor to reduce likelihood of damage and to interface with other automation systems.

Using last week's EMO 2005 machine tool exhibition to launch its MultiDeco 20/6be and 20/8d, and the Deco 20s CNC automatics, Tornos reported a very successful show.

The recent EMO exhibition in Hanover, Germany, proved a resounding success for Swiss CNC automatic lathe builder Tornos, as it sold a number of machines off its stand. Following the April, 2005 launch of the Deco 8sp and MultiDeco 32/6c turning centres, the Swiss turning centre manufacturer extended its product range, using EMO as a platform to launch the MultiDeco 20/6be, MultiDeco 20/8d and the Deco 20s. UK BTMA member WML Engineering was looking for a new turning centre and believed the new Deco 20s was the ideal machine for the company's requirements.

The Swansea based manufacturer is the first company in the world to order the exceptional new Deco 20s.

The Deco 20s is the second machine to be launched in the s-line range and is geared towards simplicity coupled with strong mechanical elements to guarantee high precision.

With six linear axes, the machine has been designed to produce reasonably complex parts up to 25.4mm diameter with an excellent price-to-potential ratio.

WML director Jason Meir comments: 'The Tornos Deco 20s complements our current Tornos Deco 20a machines'.

'WML has a requirement for very small batch runs and the simplicity and versatility of the Deco 20s fills this gap perfectly'.

'An additional advantage is that the machine can interface with our TB Deco controlled Tornos machines as well as operating in ISO code'.

'All these attributes make the machine ideal for our work in the medical sector.' Tornos developed the Deco 20s machine to respond to the market requirements of the medical, automotive and general manufacturing industries.

The exceptional strength and power provide the lathe with a very large machining capacity whilst the 22 tool positions give the Deco 20s exceptional flexibility.

The ergonomic aspect was designed to simplify the use of the Deco 20s.

The machining area is large and well ventilated and all pre-adjusted tools are easily accessible.

Subcontracting competitors had difficulty drilling a 0.3mm diameter hole 9mm deep through a component - now machined in a CNC sliding head auto in 2.5 minutes and not days.

AEL (Dorset) of Blandford Forum, UK, has grown tenfold in its first two years of business. The company that started operating out of one partner's garage, largely credits its success to impeccable customer service and the willingness to invest in high technology equipment such as the Tornos Deco 20a. Until recently, AEL were using two turning and two machining centres backed up by a network of subcontractors to service the aerospace, electronics, medical and defence sectors.

AEL director David Ross says: 'Our work just kept growing and although our XYZ fixed head turning and machining centres were capable of producing the majority of our work, we had no capability for the smaller, more complex, volume parts'.

'For example, we were producing a complex injector assembly for the food industry which was going to five specialist and very expensive machining subcontractors giving major logistics and costing problems.' 'We were subcontracting out GBP 15-17,000 of that type of work each month with the potential to increase sales value with substantially increased margins if we could offer our customers the appropriate capacity and capability'.

'At that point we realised we needed a high specification turning centre and having considered many options, eventually decided on a Tornos Deco 20a which was delivered in April 2005'.

'We now produce these parts in-house with one subcontract brazing operation' Ross added: 'The purchase of the Deco 20a not only solved our immediate problems but also opened doors for us that would have previously been unachievable'.

'Another major customer had been having difficulty finding a UK supplier that could meet the high quality and lead times required on a range of critical parts'.

'After many attempts, they settled into a pattern of buying large quantities at long lead times from the US.

Having seen our Deco and the history we had with them on smaller volume parts, they agreed to conduct trials with us'.

'The Deco was extremely successful in producing the parts; its ability to change from one variant to another quickly enabled us to quote competitively.' AEL competitors with alternate sliding head lathes were bidding for the same job but were having difficulty efficiently machining components from hexagonal bar.

The customer specification dictated that the bar must be bead blasted prior to machining to give the ultimate finish required.

As all users of sliding head machines will be aware, the guide bush will leave a witness, which on normal hexagon work is acceptable.

Competitors using alternative sliding head technology were unable to satisfy the customer's stringent requirements.

In addition to marking, the competitors also had difficulty drilling a 0.3mm diameter hole 9mm deep through the component.

A combination of the rigidity of the Tornos backed up by the Tornos engineers' ability to draw from world wide experience of difficult applications and appropriate tooling, paved the way for AEL to successfully produce samples and ultimately win the contract.

The 13 employee company now produces the component in 2.5 minutes whilst competitors could only manage a handful of parts in two weeks'.

' 'We won the contract to supply on a yearly order in Kan Bans of 700 parts'.

'On the strength of this performance, the customer has now asked us to consider seven further parts,' continues Ross.

The purchase of the Deco has considerably reduced AEL's subcontract base and taken huge cost out of the business.

The company now has plans to add further Tornos machines to its portfolio.

Machining anything from brass and aluminium to stainless steel, inconel and mnemonics, the Dorset based company has recently won a contract to produce small connectors for the aerospace industry.

This would have previously been beyond its scope without the addition of the Deco 20a.

Ross concludes: 'It is the Deco's exceptional build quality combined with superb technical backup, unbeatable cycle times and rigidity, but most importantly, efficiency; that has complimented our business'.

'The Deco epitomises quality and has given us a real advantage in a highly competitive field'.

'I want a machine that I can set, hit the start button and walk away from'.

'The Tornos gives me that confidence'.

'In my opinion, for the best all round package, Tornos is the only choice.'

Advanced CNC sliding head automatic lathe with two Y-axis cross feeds each to the turret and toolslide allowed a subcontractor to machine parts for its first original product.

John Harrison, the managing director of Microform Precision Engineering of Clayton West, just outside Huddersfield, UK, has achieved the goal of many subcontract (subby) machinists, that of successfully developing his own product. Having purchased a Citizen C16 CNC sliding head auto in mid-2004 from NC Engineering of Watford, UK, he then decided three months later that a top of the range Series 3 Citizen M32 -V with two Y-axis cross feeds each to the turret and toolslide was what he needed to produce components for his patented electronic contact probe and tool touch sensor, as well as growing his business in production machining. Microform Precision was originally set up by Harrison and his wife in 1977.

It bought its first CNC machine in 1989 and 10 years later moved into the current premises when they were first built.

The company has recently recruited works director James Vaughan who is mounting a charge to progress the business into a turned parts specialist where the newly installed Citizens play a key role to achieve a target of tripling the turnover with the same five employees who already run the firm through a seven day week 24h day regime.

And, already Vaughan has had his goals recognised with CNC sliding head autos contributing to the winning of one of two supplier credibility awards from a US customer, a certification that is highly sought after by its 120 suppliers.

The reason Harrison developed the probe and tool sensor was that he used proprietary probe systems on his machining centres and milling machines but maintains: 'Like many users I was frequently damaging the stylus by running the probe into the job'.

'I reckon that any electronic device fitted to a machine tool should be rugged enough to stand abuse'.

'So I decided to develop my own which is considerably more competitively priced than others on the market.' His probe and tool setting sensor has been designed for use on machine tools having an over travel of 6mm in each of the X, Y and Z axes.

It has a repeatability claim of better than five microns and has a robust shank 20mm long is able to access difficult areas using a 6mm diameter probe tip with flats rather than the traditional sphere.

Mill/turned parts will only now be produced on the two citizen machines which will provide the extra capacity required for more difficult single cycle work to replace an existing four year old sliding head auto described by him as: 'Not one of the best purchases I made.' Vaughan supports the statement offering that the Citizens were immediately more impressive and as an example, the first job set up on the C16 did not require an offset adjustment for four days even while running around the clock'.

''The machine it replaced would move 0.04 to 0.05mm every time the guard was opened,' he says.

The C16 was the first Citizen machine in the UK to feature the oversize bar capacity of 18mm, 'Just in case,' says Vaughan, covering a capacity between 8mm and 18mm.

It also had the first duplex opposed head driven toolholder which enabled endworking at both the main and subspindles from a single tool position with cutters up to 8mm diameter.

It has a depth capability of up to 30mm in each direction.

The capacity of the M32 overlaps the C16 holding a bar size between 12mm and 32mm, it also has the 2000 lb/in2 CoolBlaster, high pressure coolant system, a programmable part retrieval system to clear working area and NC Engineering's Alarm Alert automatic call-out.

This is fitted to both machines should problems occur when running in lights out mode, and calls the duty operator on either mobile phone or land line giving details of the machine stoppage such as material shortage or process malfunction.

The tool capacity of up to 82 tools was important to Vaughan on the M32 because he is practising fast changeover techniques, leaving the machine set with common tools and grouping like materials and similar parts together.

He also maintains the machines were selected in order to provide a practical single cycle 'one-hit' solution to account for any feature, geometric tolerance or surface finish requirement set by the customer.

Already Microform Precision Engineering produces a wide range of parts in Delrin, plastics, aluminium, brass and stainless steels'.

''You need flexibility and we have turned to a new chapter in our business to provide a finished part from the one machine'.

'Previously, we had wasted hours on secondary operations and the associated problems,' Vaughan maintains.

Vaughan and Harrison both firmly believe that delivery, quality and service are key: 'You ca not ring the Far East and ask for panic order parts in two or three days, that is our delivery objective and we have now planned with the tooling set-up to be able to split, say a 5,000 batch, set-up for a few hundred parts against a special order and quickly switch back to the original CNC program and contract.' That has meant a considerable spend on tooling to give flexibility but he confirms even deburring is simple on the Citizens: 'You just program the interpolation required to take off a whisker around the profiles and the job is done, ready for washing,' says Vaughan.

He is a great believer in the use of form tools and makes a lot of his own such as flat form tools step and combination drills.

This enables him to combine undercuts, grooves and diameters, chamfer and counterbores and combination drill cross holes.

Often one tool will do a whole series of parts which saves cycle time from tool indexing and having to perform multiple passes'.

''It also helps when simultaneous cutting with a form tool when up to three tools are engaged at the same time enabling several features to be produced very quickly,' he says.

The use of CoolBlaster follows the success of other Citizen M32 specifiers with tool life extended by at least 50% on 316 stainless steel, peck drilling eliminated and the benefit of much better swarf control.

Most important is the secondary collet cleaning between parts plus the bonus of cycle time improvement by up to 20%.

Among the jobs now falling under the single operation philosophy is a pin assembly for off-road vehicles.

This 75mm long 6mm diameter shaft with circlip grooves used to have to be ground to 15 micron tolerance with serrations produced in the centre for push fit assembly to a mating block.

Now the pin is made complete in one operation with a knurl in the centre which has been accepted by the customer.

Altogether, some 30s have been saved on production of the part.

A balancer shaft for a fuel injection system has been cut from two to one operation and a square flanged component with a spigot, central bore and four drilled and tapped pitch circle holes has shown a massive 70% saving on production times by combining four operations into one.

Cutting with three tools simultaneously the round bar is milled square, the centre bore drilled and bored and outside diameter of a spigot turned before a special ground subland drill is used to drill and countersink the four holes and interpolate around the part to provide a precision deburred edge.

But the classic is a medical industry connector made from 24mm diameter 316 stainless steel bar which has an offset eccentric bore that required a total of six operations to produce.

Previously production methods were made worse because tight process tolerances had to be applied to ensure fixturing would reproduce a blended milled form which then had to be finally polished by hand.

This part is now produced in one single cycle with all geometric relationships easily met, size and surface finish are now regarded as 'as machined', which eliminates all the additional handling, fixturing, inspection and polishing.

High-speed CNC automatic lathe - with a linear axis drive, Y-axis and 36 driven tools - can apply three cutting tools simultaneously on bar components up to 65mm.

The Sprint 65 linear offers numerous advantages for the bar machining of workpiece diameters up to 65mm., as well as for chuck workpiece diameters up to 175mm. The machines are designed with impressive linear drives in the X3-axis, a Y-axis in the standard version, a 55 deg slanted bed and three dynamic 12x turrets. In the manufacturing process, the simultaneous utilisation of up to three tools leads to the highest available productivity for non-stop operation, both for complex or simple turning workpieces.

The new Sprint 65 linear now completes the Sprint linear Series for the highly efficient machining of workpieces in the diameter range up to 65mm.

With the standard-equipped 3 turrets and the Y-axis, this new machine can perform simultaneous machining with three independent tools.

This leads to shortest cycle times during machining.

In addition, the 36 driven tools on the Y and C-axes allow the machining of complex workpieces.

In short: the new automatic lathe Sprint 65 linear is the perfect alternative in the machining of short turning workpieces for small and medium lot sizes.

Especially the utilization of pioneering linear drive technology in the X3-axis contributes greatly to this achievement.

The machines of this series not only offer high dynamics with acceleration up to 1G and fast rapid traverse speed up to 40m/min, but their direct measuring systems also lead to maximum precision.

An additional productivity increase is achieved by the integrated spindle motors on main and counter spindle, each with rotational speeds of 5,000 rev/min.

After finishing, the workpieces are transported out of the work area through the counter spindle, which again reduces idle times and leads to even shorter job times.

The bar feed itself does not impact productivity, because this step in the process occurs parallel to the ejection of the workpieces.

As an option, the new Sprint 65 linear can also be equipped with an integrated gantry system, both for bar and chuck machine.

Drives and CNCs are delivered as packages, from either Fanuc or (as an option, new at the EMO) from Siemens.

The innovative control technology of the servo motors and the digitally controlled drives ensure control processes with the highest possible speed, precision and data transfer rate.

The CNC itself is located in the DMG SlimLinePanel with 15in TFT-screen, which can be swiveled, allowing the operator to always move it into the best position.

In addition, easy-to-use functionality for automatic programming helps the operator perform his task.

Finally, the integrated software for tool-wear control and automatic access to spare tools, ensures the highest degree of operational safety in three-shift operation, even in the sector of hard-to-machine materials and large series.

Innovations - Sprint 65 linear: * Up to three driven tools in operation simultaneously.

* Linear drive in X3 for maximum precision on both spindles.

* Three tool revolvers, each with 12 driven tools.

* Y-axis in the standard version for use on main and counter spindle.

* Two cooled spindle motors for high availability.

* Hydraulic quill fitting for main and counter-spindle.

* Standard-equipped with conveyor belt handling system for finished workpieces.

* tool wear control and sister tool system for increased productivity in three-shift operations (optional).

* Automation with integrated gantry-system both for the bar and for the chuck machine (option).

* DMG SlimLinePanel with 3D controls and 15in TFT-screen.

Cam-operated automatic lathes all over the UK are being replaced by multi-axis CNC sliding-headstock lathes, as OEMs and subcontractors realise 'one-hit', 'lights-out' working brings back work.

Cam auto's all over the UK are being replaced by multi-axis CNC sliding-headstock lathes, as OEMs and subcontractors realise that they can harness the machines' one-hit, lights-out production capabilities to compete with low-wage economies. A recent convert is connector manufacturer, Harwin, Portsmouth, which invested in seven Star sliders during an 18-month period to mid 2005. At the same time it sold off more than 20 cam-operated lathes, leaving 50 or so on site to be replaced over the next four to five years.

The production output from six of the Star lathes, all entry-level SB-16 bar machines, equals that of the previous 20+ cam auto's.

The seventh CNC slider, a Star SR-20RII, was bought specifically to produce a family of 20 high-voltage posts which form part of a new, 90-degree, co-axial connector developed by Harwin.

The latter machine has resulted in a 60% saving in the cost of machining the connector posts compared with the price previously paid to a subcontractor, which was manufacturing the components in two or three operations.

As a result, it was having difficulty holding tolerance, and delivery was often slow.

On the Star multi-axis lathe, the post is reliably mill-turned to the required accuracy in a single visit to the machine.

According to its size, the component is produced from 16mm or 20mm diameter brass bar.

In the main spindle, operations involve turning the front face, profile turning the OD, drilling a hole down the centre, slotting, and milling a box-shaped body.

After synchronous pick-up in the counter spindle and part-off, material is milled away from the body to leave two parallel legs at 90 degrees to the spindle centerline, a cross hole is drilled and a slot is milled to break into both this hole and the central bore.

Depending on variant, the total cycle time is from 40 to 60s, the majority being prismatic machining rather than turning, such is the versatility of these lathes.

Said Ricky Phillips, Turning Shop manager, 'Our cam auto's formed Harwin's total manufacturing capability up to the 1980s, when the company invested in high-speed stamping for producing higher volume connectors.

The trouble was that production runs were starting to fall, which made setting up cam machines uneconomic, so in 1987 we bought an early Star RNC CNC slider which was easier to set and could compete on speed.

Its reliability has been second to none and the machine is still in constant use today, producing accurate parts round-the-clock.

Batch sizes continued to get smaller as specials became more common and customers were less willing to hold stock.' Phillips and his team were having to spend four to eight hours resetting a cam auto which would sometimes run for only one day to produce, say, 5,000-off connector parts.

He says that a run of at least 50,000-off is needed to justify resetting a cam machine.

Now, Harwin is able to machine small batches of connector parts economically on the Stars, even when cycle times are as short as 10s, as set-up takes typically one to two hours for a complete changeover'.

Phillips said: 'However, with space for so many static and driven tools in the working area and by standardising on a few bar sizes, set-up can be as quick as 15 minutes if the bar and tools are unchanged and a program simply needs editing at the machine.

The ability of the Stars to generate a large throughput of parts, 24 hours a day including unattended operation overnight, leaves spare capacity to run non-connector subcontract work, such as components for the automotive, aerospace and medical industries.

In these cases, 5,000-off is a large batch and one-offs are frequently undertaken.

Drawing tolerances are down to +/- 0.03mm, although +/- 0.01 to 0.02mm is routinely held even over an entire lights-out shift, according to Phillips, who commented that this level of accuracy gives a stable platform for meeting customers' Cpk requirements.

He continued, 'The transition from cam auto to CNC slider has been very smooth and our operators readily took to the Stars, which they find easy to program at the Fanuc control or off-line.

Service from Star's Melbourne head office has been impressive, with any small problems usually sorted out over the telephone.

Stockholding of tooling and spares is also good, and we have used their applications engineers to help us out with the occasional program for new prototypes, such as the 90-degree connector post.' As a postscript, Phillips commented generally on the relative merits of sliding- and fixed-head turning for connector manufacture.

When the early Star RNC turning centre was installed, Harwin also invested in a CNC fixed-head lathe and carried out comparative trials.

Following customer demonstrations at the recent EMO 2005 machine tool show, a GBP 250,000 order has been taken by the company's subsidiary, Star GB, for the supply of three sliding-headstock lathes.

Following customer demonstrations on the Star Micronics stand at the recent EMO machine tool show in Hannover, a GBP 250,000 order has been taken by the company's subsidiary, Star GB, for the supply of three sliding-headstock lathes, two SB-16s and an SR-20RII, to a contract manufacturer in the UK. The application revolved around the high-speed production of a simple shaft component where annual output was critical to the customer's decision-making process. Star GB worked jointly with its Japanese colleagues to achieve the required cycle times and win the order.

All three lathes are fed by German-built FMB bar magazines, for which Star GB is sales agent in the UK and Eire.

With a total tool capacity for 80 tools of which 20 can be drivens, the latest CNC sliding headstock turn/mill centres can independently use three tools simultaneously.

This capability to simultaneously machine with three tools comes from the 10 station, all-driven turret, a nine station gang tool slide and a separate triple tool fixed unit. These tooling stations enable floor to floor times to be dramatically reduced and accommodate users that want to carry part set or common tooling on the machine to speed changeover and increase machine utilisation. This latest development from the top of the Citizen range M-Series CNC sliding head machine stable has the distinct advantage of being able to initiate a Y-axis crossfeed to the all-driven 10 station tool turret, now able to carry up to eight tools per position through new tool holder developments by Citizen for both front and back machining.

And with the separate Y-axis feed to the nine tool station gang tool slide, this is able to present four driven tools and five turning tools for front machining.

This tooling arrangement of the two Y-axis driven slides provides maximum flexibility for high orders of milling and off-centre drilling and tapping performance.

In addition, the triple tool unit, with the option to provide three stationary or one stationary and two driven tools provides further opportunities to perform back machining operations.

Central to optimising the benefits of the new control system is the considerably faster data processing and software that accelerates the use of the control's macro programs enabling simultaneous control of up to eight axes.

This capability also enables idle times to be cut by up to a quarter.

Here, the rigid cast iron slant bed structure of the M-16 machine frame enables tooling performance to be optimised and high orders of accuracy and surface finish to be achieved at the main 2.2kW, 10,000 rev/min spindle and the 0.75kW, 10,000 rev/min subspindle.

A major advantage of the M16-V with its Y-axis feed and ability to carry multiple tools at each tool position of the turret is that idle time can be further reduced because the adjacent tool can be engaged without the turret having to be indexed.

The Y-axis also enables tool centre height to be quickly adjusted and set using compensation at the control and this feature also creates additional flexibility when using milling cycles.

Among the application capabilities available on the machine are rigid tapping on main, subspindle and rotary tool positions, constant surface speed and continuous threading cycles for both main and subspindles, polygonal special machining, thread whirling and gear cutting.

Functions such as thread lengthening at high speed, synchronous threading by fast tap retraction and a fast program check routine that will provide cycle time calculations without any need for mechanical movement, further help establish benefits of advanced M-Series Citizen technology.

A programmable gripper-based off-load device is available that minimises unloading times and protects delicate components from damage and a long part adapter is available to accept parts longer than the maximum 200mm stroke enabling parts up to 400mm to be effectively machined.

Also the well-proven Cool Blaster high pressure 2,000 lb/in2 coolant system that improves tool life, surface finish and metal removal rates can be specified as an NC Engineering fitted option.