A subcontract company's success in 'growth' sectors has not happened by chance but by the tight management and control exercised over all operations and machine tool purchases.

Precision engineering subcontractor's continued growth is down to rigorous planning, a disciplined focus and strategic investment in Mills: Doosan Daewoo advanced machine tool technology. Market-leading Poole-based specialist subcontractor - Aercomp Precision Engineering - is experiencing significant growth and has done so since its creation eight years ago. The company, established in 1998 and now employing 17 staff, has made its name and built its reputation manufacturing high-precision complex parts for the aerospace and electronics sectors.

The company's success in these demanding 'growth' sectors has not happened by chance but rather can be explained by the tight management and control exercised over all operations by Aercomp's directors and founders Glen Marsh and John Mulqueen.

Indeed it is the company's commitment, dedication and attention to detail that has seen Aercomp become a 'value-adding' preferred supplier in the aerospace supply chain and explains how 70% of the company's business now comes from this sector.

It also helps explain Aercomp's full order book; a move completed 2 years ago to its present 8,000ft2 facility - and why the company operates a five-day per week 24h shift system too.

Aercomp specialises in the manufacture of small series, and prototype complex aero-engine parts.

These parts, mainly made from exotic heat-resistant alloys such as inconel and Nimonic along with other difficult-to-machine materials are time consuming to manufacture and without the sophisticated and be-spoke workholding and fixturing solutions that Aercomp specialises in producing would be virtually impossible to manufacture commercially.

However, the workholding prowess of Aercomp is only part of the story.

In addition the company makes regular strategic and prudent investment in the latest machine tool technologies as a route to improving component accuracy, reducing lead times and driving down the cost per part.

As part of this process Aercomp has made significant investment in Mills: Doosan Daewoo advanced turning technology.

To increase its capability and capacity Aercomp, in 2005, invested in three new machine tools from Mills and now has a total of eight machines supplied by Mills at its facility along with five vertical machining centres and one other CNC lathe.

The new machine tool investments made in 2005 are as follows.

One 240 LC 2-axis lathe - the Puma 240 LC is a compact, high-performance lathe with 76mm bar working capacity, a high-torque 18.5kW 3,500 rev/min spindle and 30m/min rapids.

* Two 240 MSB multi-functional turning centres - the Puma 240 MSB is a high-productivity, multi-tasking turning centre (mill-drill capability) with 65mm bar working capacity, a 15kW 4,500 rev/min main spindle and 5.5kW 6,000 rev/min sub-spindle.

All three machines have helped to increase Aercomp's manufacturing capacity and provide the company with additional production flexibility.

As stated above aerospace precision sub-contract work accounts for some 70% of Aercomp's turnover.

The remaining 30% comes from the electronics/telecommunications sector in particular the manufacture of precision components for ultra high-speed spindles (500,000 rev/min) used to machine minute holes and features in circuit boards.

Unlike its aerospace work which is characterised by high precision and low volume/small series manufacture Aercomp's 'electronics'/ spindle assembly work, whilst requiring high accuracy and repeatability, is much more high-volume in nature with batch runs of 60,000 components not being uncommon.

To manage both types of work effectively - requires robust planning and first-class production/work scheduling and a vital and constant element in the equation is access to and availability of reliable machines on the shop floor.

Said John Mulqueen, director at Aercomp: ' We run a tight ship here at Aercomp.

Everything is finely balanced to ensure that we optimise our production.

The additional capability we now have from our latest Doosan Daewoo machines gives us more flexibility and has presented us with opportunities to improve our performance.' He said: 'Eight years ago when we created Aercomp the first machine we invested in was from Mills.

Since then we have always found that Mills' technology, applications help and support, after-sales services and general all-round proactive approach fits in well with our operations.'

An extremely stiff Y-axis has been integrated into a turning centre's structure and stands on an extremely wide-set guide rails to ensure top precision when performing difficult cutting tasks.

New customers are understanding the Emco's new high-performance turning centre. Because just like its larger sisters Maxxturn 65, 95 and 110, the Maxxturn 45 - with a 45mm bar capacity - is also a perfect solution for low-cost complete machining off-the-shelf. * Extremely stiff Y-axis - fitted with a counter spindle, driven tools, a high-precision C-axis and very fast rapid-motion speeds, the Maxxturn 45 offers everything the customer needs to manufacture complex turned and milled parts, not only in high quality, but also cost effectively.

The special highlight of the new Maxxturn 45 is the Y-axis.

It has been integrated into the machine structure and stands on an extremely wide-set guide rails.

This ensures extreme stiffness and top precision, even when performing difficult cutting tasks.

In addition, the Maxxturn 45 has a Y axis with a large travel, which also increases the number of machining options when turning and milling.

The Maxxturn 45 is available with either a Siemens or Fanuc controls - and Shopturn or Manual Guide are standard equipment.

* Tailored automation - as with all Emco machines, there are perfectly customised automation fittings for the Maxxturn 45 as well.

There is a swing loader for automatic loading and unloading.

For bar work there are three different bar loaders on offer: a classical 3m bar loader, the Emco short-bar loader LM800 for limited floor space and the Compact Load E45.

CNC lathes and mill/turn centres are robust and handle big and heavy duty machining applications in difficult-to-machine materials - Inconel, SS, hard steels and nickel/chrome alloys.

Ayrshire,UK-based precision engineering company - Jigs and Fixtures - specialises in the manufacture of large, high-quality, complex components - predominantly for the oil/gas sector - which today accounts for over 60% of the company's annual turnover. The company, established 30 years ago, and now employing 92 staff (70 involved in production), has positioned itself as a prime mover and shaker within the oil/gas sector - and has focused its manufacturing skills and resources on the high, added value end of the sector. Said William Hyslop, Partner at Jigs and Fixtures: 'The sector is competitive - and to survive and grow within it - we have streamlined our manufacturing processes and systems in order to ensure that component quality, reliability of delivery and cost-competitiveness are never compromised.' An integral element to streamlining its systems (and addressing the above critical success factors) has seen the company make strategic and telling investments in the very latest advanced CNC machine tool technologies.

These investments have seen the company significantly strengthen its manufacturing capabilities in recent years - and in doing so has forged strong relationships with machine tool specialist - Mills Manufacturing Technology - based in Leamington.

Jigs and Fixtures has an impressive array of advanced Doosan Daewoo CNC machine tools supplied by Mills.

These include: Two Puma 400LM long-bed CNC lathes - (2155mm Z-axis, 116.5mm bar working capacity, 1014mm workpiece length, 12-station tool changer and 7.5kW 3000 rev/min milling capability).

Two Puma 700 LM CNC long-bed lathes - (3235mm Z-axis, 164mm bar working diameter, 3200mm workpiece length, 12-station tool changer and 11kW 3000 rev/min milling capability).

One Puma 2000SY 6-axis turning centre - (65mm bar working capacity, 510mm workpiece length, full C-axis on main and sub-spindle, 12-station tool changer and integrated bar-feeder).

Three MX 2500ST multi-axis Mill-Turn Centres - (255mm chuck size (both spindles), bar working diameter 76mm (both spindles), 1020mm workpiece length, 40-position tool changer, +/-120 deg B-axis and +/-80mm Y-axis, 18.5kW 10,000 rev/min milling capability).

The machine tool technology at Jigs and Fixtures' disposal provides the company with a number of business benefits.

The multi-axis machines mean that complex jobs can be setup and be completed more effectively and efficiently.

This 'one-hit' machining capability helps prevent the creation of production bottle-necks and, owing to reduced setups - part accuracy and manufacturing productivity (i e, throughput) are improved.

The Puma lathes are robust and are capable of handling big and heavy duty machining applications in difficult-to-machine materials - Inconel, Stainless, Hard steels Nickel/Chrome alloys etc They provide Jigs and Fixtures with high metal removal rates, rapid and responsive positioning and high-speed turret indexing all of which help improve cycle times for jobs that can take up to 80h to complete and require tight tolerances (+/-0.005in or better) across the part.

The milling capability and programmable tailstock on the Puma 400's and 700's extends the functionality of both machines still further - again reducing cycle times and increasing machine tool utilisation.

The skills and expertise of Jigs and Fixtures mean that the company is very much positioned in the high precision, added-value end of industry - and its 'blue-chip' customers reflect this.

Projects undertaken by the company, whilst still certainly demanding in terms of lead times, cost and quality, are not in the commodity, 'loss-leader' bracket - a situation many UK manufacturers without the requisite advanced technologies are now finding themselves confronting.

Concluded Hyslop: 'We can afford to be more selective with the work we take on thanks to the investments we have made.

We have the technology and the infrastructure in place to continue to grow - and that's exactly what we intend to do.''

In designing a multi-tasking mill-turn centre system, the builder rethought the design and construction to harness the turning ability of a lathe and the cutting ability of a machining center.
Mori Seiki's new NT Series of integrated mill-turn centers fully combines a lathe with a machining center. In designing the series, Mori Seiki completely rethought the design and construction of multitasking machines to harness the turning ability of a lathe and the cutting ability of a machining center. The NT Series employs both DCG (Driven at the Center of Gravity) technology and the box-in-box construction of the NH Series horizontal machining centers, along with the turret with a built-in milling motor from the NL Series CNC lathes.
The combination of these features is included with no compromises in terms of their performance.
Machines in the NT Series contain a B-axis that uses a DD (Direct Drive) motor, eliminating backlash and making high-speed rotation possible.
Indexing specifications for the axis cater to high precision machining requirements, allowing for input by units of 0.0001 deg.
To make the NT Series as efficient and productive as possible, special attention has been paid to machine speed.
Maximum spindle speed is 5,000 rev/min with a maximum tool spindle speed of 12,000 rev/min.
Additionally, the machines' ATC (Automatic Tool Changer) features a tool-to-tool change time of just 1s and a chip-to-chip time of only 3.4s.
Special attention to thermal displacement allows machines in the NT Series to perform at the highest levels of accuracy and precision.
The lower turret is located symmetrically in relation to the center of the spindle, forming a construction resistant to the effects of heat.
Additionally, ball screw and motor jacket cooling have been implemented to completely eradicate inaccuracy caused by heat variations.
The NT Series will make use of MAPPS III, the latest iteration of Mori Seiki's highly successful control system.
MAPPS III allows fast processing and is equipped with a collision prevention function that monitors machine movements in real time.
The controls also take advantage of the ease and convenience of conversational input, providing high-speed canned cycles that lead to dramatic increases in programming speed.
The NT Series will contain 9 models, with spindle, lower turret and no center support options bringing the total number of variations to 66.
Varieties of the machines will be brought to market sequentially.
Mori Seiki produces extremely reliable machine tools and distributes worldwide.
The U.S.
headquarters is in Chicago with offices in Boston, Chicago, Cincinnati, Dallas, Detroit, Los Angeles, and New Jersey.

A 15-axis mill-turn centre of twin-opposed-spindle configuration and may be equipped with two, three or four disc turrets - deploying up to 80 tools without a tool magazine.

The new, German-built Traub TNX65/42 mill-turning centres from UK agent, Geo Kingsbury Machine Tools, are of twin-opposed-spindle configuration and may be equipped with two, three or four disc turrets, each capable of holding 10 driven or static tools on both faces using double toolholders. So up to 80 tools can be accommodated in this conventional design of lathe. Normally for a CNC lathe to deploy such a large number of tools, its design is based on a single-station turret head with automatic tool change (ATC) from a magazine outside the working area.

As a conventional turret tends to be more robust than its ATC counterpart, higher accuracy machining may be achieved, added to which the 10-tonne TNX65/42 is constructed on a heavily ribbed, cast iron slant bed that dampens vibrations and promotes close tolerance machining.

Tool change is faster with a disc turret than when cutters are exchanged from a magazine, leading to higher productivity as well.

Balanced turning of slender workpieces or two dis-similar machining operations performed at the same time are established advantages of twin-turret turning, which is achievable at both spindles simultaneously.

The TNX65/42 takes the technology a stage further, however, with the possibility of tools in three turrets cutting simultaneously at either spindle.

In addition to travels in X and Z of 650mm and 175mm respectively, there is +/-40mm of Y-axis movement on each turret, enabling keyway milling, off-centre drilling, side face milling and similar operations to be carried out.

Even more complex components may therefore be completed in one hit, with all attendant benefits including less work-in-progress, shorter lead times, zero fixture costs and reduced manning overheads.

The result can be cycle times so quick that they would normally be associated with a multi-spindle auto.

Of symmetrical design, the machine has its turrets arranged on independent slides above and below the spindle centreline, giving maximum versatility for optimising cycle times.

Furthermore, the headstock is thermo-symmetrical and the synchronous, C-axis motor-spindles are of identical rating at 24kW / 5,000 rev/min for the 65mm bar capacity machine and 28kW / 7,000 rev/min for the 42mm bar model.

Hybrid bearings are fitted as standard for increased service life.

Control is provided by the TX8i-s running, as usual, Traub's in-house developed software.

It is optimised to the manufacturer's lathes and is backwardly compatible, allowing programs to be run that were created on earlier controls.

Realistic 3D simulation shortens set-up time and avoids collisions when producing first-off components.

On-line and off-line programming with powerful synchronisation and optimisation of up to four machining sequences can be provided by Traub's optional WIN FLEX IPS graphical object-orientated software.

Twin turret CNC vertical spindle lathe - with a smaller 'footprint' - designed for the automotive industry - machines shafts and minimises the influence of heat and during continuous machining.
Twin-turret vertical CNC lathe machines shafts Twin turret CNC vertical spindle lathe - with a smaller 'footprint' - has been designed for the automotive industry to machine shafts and minimises the influence of heat and during continuous machining. Mori Seiki is proud to announce the release of its new 2-turret shaft lathe, the NZ-S1500. Created specifically to machine shafts, the footprint of the NZ-S1500 is less than half the previous models, providing dramatic space reductions for production lines.
To increase productivity, the NZ-S1500 employs a symmetrical design in which the two turrets are aligned with the spindle, which is mounted on the vertical bed.
This layout also serves to reduce the influence of heat and improve accuracy during continuous machining, holding thermal displacement to under +/-10 micron.
The unique arrangement of the NZ-S1500's components also improves accessibility and chip disposal.
Chips fall directly into the chip pan, avoiding accumulation, and a vertical protector prevents chips from reaching the linear guide or ball screws.
The NZ-S1500 can accommodate workpieces with a machining diameter of 120mm diameter and a standard machining diameter of 60?20mm diameter.
A high-speed loader with a rotary hand function increases the efficiency of the machine.
In addition to its small footprint, the NZ-S1500 also measures just 5ft in height, allowing the operator an easier line of sight of the surrounding production environment.
Mori Seiki produces extremely reliable machine tools and distributes worldwide.
The US headquarters is in Chicago with offices in Boston, Chicago, Cincinnati, Dallas, Detroit, Los Angeles, and New Jersey.

he new Olympus STM6 series of microscopes has been specifically designed for a wide range of industrial inspection and measurement applications.

he new Olympus STM6 series of microscopes has been specifically designed for a wide range of industrial inspection and measurement applications. The range features a variety of models that covers increasing user demand for new measuring capabilities and offers more system versatility and higher performance than ever before. The STM6-LM is used for fast inspection of larger samples, and the STM6 offers the most compact microscope in its class with exceptional levels of precision and durability for today's broad research and industrial environments.

The new Olympus STM6 range of industrial measurement and inspection microscopes has been designed to perform the most demanding measuring and inspection tasks of industrial parts and electrical components.

Both the STM6-LM and STM6 models offer outstanding features with motorised focusing - a world first, highly advanced UIS2 (Universal Infinity System) infinity-corrected optics, and a high-rigid body with integrated counters.

Motorised focusing has been introduced to the STM6 series for quick and precise Z-axis measurement.

This dramatically improves operation in both focusing and the measurement of height and depth, and is equipped as a standard feature.

The Z-axis control box, which is conveniently located by the operators hand, allows both coarse and fine focusing movements to be carried out.

In addition, the auto focusing unit makes it possible to obtain stable measurement results by minimising the dispersion caused by different operators.

The space-saving body of the STM6 series is the smallest in size in this class of measuring microscopes despite its numerous versatile functions.

The highly rigid frame and measuring stage offers solid stability over long periods of operation in manufacturing environments.

The stages are embedded with glass scales for reliable and accurate measurements, and are available in three different types, 50mm x 50mm, 100mm x 50mm and 100mm x 100mm, to accommodate various sizes of samples.

The STM6-LM is equipped with a clutch-type stage which provides a large measuring area (250mm x 150mm), and all X and Y movements are clutch-controlled.

This allows the user to change quickly between coarse and fine movements by simply moving a lever, and free movements on the X/Y axis and X/Y plane allows larger samples to be accurately inspected.

It is also possible to measure mulitple samples on the stage at the same time.

A precise read-out counter (0.1 and 0.5um) has been integrated with the column of the microscope body, with the display comfortably positioned at the ideal observation eye-point.

The operator can confirm the measuring value with only a slight change in eye angle, allowing easier concentration on the sample observation and positioning.

The STM6 stand also accepts fibre optic cold illumination for minimising the heat effect on the sample and microscope body.

The compact and functional, ergonomical design of the STM6 series offers a versatile combination of microscope bodies, stages and motorised units.

The user can select or add from a four model lineup and a variety of reflected light illumination systems to perform a full range of different jobs.

A range of add-on units is also available for both STM6 and STM6-LM microscopes, including an auto focus unit to measure height and depth, and a transmitted light edge sensor unit, which automatically detects a sample edge for accurate measurement.

Larger vertical turning centre (pick-up spindle) takes workpieces of up to 340mm diameter and 160mm height and main 58kW spindle motor aplies a torque of up to 930Nm.
As a complement to the VL 3 and VL 5 Standard Turning Centers Emag has introduced the new VSC 7 for larger, heavier workpieces. This ensures that sub-contractors and tier-1 suppliers of, for instance, components for the power train of HGVs can now also profit from the large number of advantages offered by the vertical turning centers from Emag. The most outstanding attribute of the VSC 5 / VSC 7 series from Emag is the successful combination of sophisticated technology and highest quality on the one hand and the low capital outlay and minimum footprint - and thus optimal economic performance in the factory - on the other.
The VSC 7 Vertical Turning Center corresponds in construction and equipment content to the well proven vertical turning centers of the VSC series from Emag.
Thus, for instance, they feature the usual Mineralit polymer granite machine base with its excellent dampening properties, which ensures extended tool life and a better surface finish.
The machine base carries the gantry with the overhead slide unit that contains the main spindle.
This guarantees symmetrical force distribution and a high degree of rigidity.
Spindle motor, main spindle and quill unit, turret, electrical cabinet and machine base are all fluid cooled.
A twin-circuit heat exchanger maintains the machine temperature within tight limits of the ambient temperature.
The Z-axis quill unit's hydrostatic bearing, the 160mm diameter of the main spindle's front bearing and the sturdy VDI 50 tool receptors in the turret ensure that milling and drilling operations are carried out with the necessary rigidity and an absolute minimum of vibration.
The turret accommodates 12 turning tools or, alternatively, up to 12 live drilling and milling tools.
A chuck of 400mm diameter takes workpieces of up to 340mm diameter and 160mm height.
The main spindle motor has a power rating of 58kW, a maximum torque 930Nm and reaches speeds of up to 3600 rev/min.
The workpieces are loaded by so called 'L-automation' with flexible carrier prisms that are aligned by an NC axis.
This allows for varying workpieces to be conveyed to the pick-up station in 4 to 6s, without the need for resetting.
Where required, two machines can be interlinked by component turnover station and thus converted into a flexible manufacturing cell that complete-machines the component, in this case at front and rear.
To ensure that given workpiece tolerances are checked and held, a measuring probe - located outside the machining area - can be integrated into the process.
Measuring the workpieces while they are clamped in the main spindle allows the CNC control system to instigate possible tool offsets.
This ensures that given tolerances are held and the component quality maintained, even during unmanned production.
A combination of well proven modules recognised by the manufacturing industry as standard components and a small number of also standardised optional components, allows Emag to make the VSC 7 available within a few weeks.
This ensures that sub-contractors and 1st-tier suppliers in particular can manage to do the expected splits between maximum process capability and finishing accuracy, minimal expense and highest degree of flexibility.
To achieve this, they use well proven, reliable machines and unreservedly enjoy all the advantages the vertical turning center offers, such as maximum flexibility, productivity and process capability.

Vertical turning centre shown at the recent METAV exhibition completely machines parts up to 800mm diameter in a single set-up and replaces the vertical turret lathes previously employed.
With its VLC series of vertical turning centers EMAG proves again that it can come up with yet another innovative idea for a high-efficiency production tool. The VLC 800 Turning Center, shown at Metav from the 20th to the 24th of June 2006, complete-machines workpieces of up to 800mm diameter in a single set-up and thus replaces the vertical turret lathes previously employed for the machining of this size of component. Faithful to the motto 'Eliminating wasteful workpiece tourism through process stream consolidation', the three frame sizes of the VLC - 500, 630 and 800 - reduce waiting and transport times of individual machining processes.
They also cut set-up times and floor space requirements, as the number of machines and storage facilities required is reduced.
The resulting flexibility and the integrity of its process capability make the VLC series ideal for the small and medium size batch production.
With these turning centers Emag has reinforced the principle - introduced by the company in 1992 - of providing vertical turning machines, now also for larger workpieces.
To accommodate long axis travels and - at the same time - allow ergonomically favourable access to the machining area, the X-axis has been positioned across the operator's access window.
With an X-axis travel of 2350mm the VLC 800 also applies the pick-up principle developed by Emag.
The raw parts are conveyed to and clamped in the spindle and taken to the machining stations in the tooling zone.
The sturdy main spindle with its power rating of max 100kW, a torque rate of up to 4300Nm and speeds of max 500 rev/min is contained in a quill unit that travels in Z-direction.
The non-friction, wear resistant, play-free hydrostatic guideway for the quill has optimal damping properties.
This minimises tool wear - even when using interrupted cuts - and guarantees an excellent surface finish, supported by the machine base in Mineralit, a mineral cast compound that has particularly good damping qualities.
Spindle motor, main spindle with quill unit, turret, electrical cabinet and machine base are all fluid-cooled.
A twin-circuit heat exchanger maintains the machine temperature within tight limits of the ambient temperature.
All this allows the VLC turning centers to machine even large workpieces at tolerances in the hundredth millimetre range.
Emag's well proven modular design of the VLC provides for ample space in the machining area to accommodate equipment for a large range of production requirements.
Possible specifications include one or two fixed turrets that can be optionally equipped with life tools and which can - also as an option - travel a second X-axis.
And optional Y-B-axis unit can be equipped with a drilling or a milling spindle with tool magazine.
The great stability and precision of these machines also allows for grinding and hard machining operations to be carried out.
Tooth profiles can be machined with a gear hobbing attachment from Emag-Koepfer.
To ensure that required workpiece tolerances are held, a measuring probe - mounted outside the machining area - can be integrated into the process.
To ensure that a larger number of manufacturing facilities can enjoy the twin-advantages of combined process sequences and process stream consolidation in future, Emag has further extended its series of vertical turning centres for larger workpieces with the VLC 1200 for components of up to 2000kg in weight and a max diameter of 1200mm.
Emag now offers the most comprehensive range of vertical turning centers with fully integrated workhandling and measuring and a multi-functional machining capability.
These machines, which can be expanded - using standard optional equipment - into customised production centers for complete-machining, now allow you to manufacture components of between 10 and 1200mm diameter.

Two in one go - vertical turning centers combine either end-machining and finish-turning operations, or - on its two-spindle variant - pre- and finish-machining of both shaft ends.
Emag showed its VTC 250 DUO Vertical Turning Center at METAV Dusseldorf, Germany. The machine meets further demands for the consistent application of combined process sequences. Its users will profit from minimal throughput times, greater integrity of the process capability and higher precision.
The VTC 250 DUO will machine shaft-type workpieces of between 70 and 630mm (optionally up to 1000mm) length, up to 140mm in diameter and 20kg in weight, starting with the forging blank or billet and finishing up with a complete-machined component.
For this purpose the machines are equipped with three turrets, a main spindle and a separate clamping station.
Once the first turret has collected the raw part from the loading point and conveyed it to the clamping station, it proceeds to machine both ends with its two sets (one each for front and rear) of up to four life tools (power rating 38kW, speeds of max.
1400 rev/min).
On completion of the end machining operations turret No-2 conveys the component to the second machining station, where it is clamped in the main spindle chuck and - supported by a tailstock (and, optionally, by CNC steadies) - finish-machined in 4 axes by up to 11 tools each in the second and third turrets, where power ratings of 29kW, torques of up to 200Nm and main spindle speeds of up to 5000 rev/min together with direct-drive feedrates of up to 40 m/min produce short cycle times.
The VTC 250 DUO can also be equipped with a high-powered main spindle of 38kW and 300Nm torque rating as an option.
A further option would be to have the VTC 250 DUO equipped with two main spindles.
This variant is suitable for pre- and finish-machining in a single process sequence.
It also allows for the finish-machining of both shaft ends, whereby the workpiece can be turned around during transfer from one to the other spindle.
Compared to the sequential machining of shafts on a number of machines, this extensive application of combined process sequences on a single lathe considerably shortens throughput times.
Complete-machining in a single production sequence also noticeably reduces component manufacturing costs.
Combined with its high degree of flexibility in handling different workpiece lengths the VTC 250 DUO offers great advantages also in the manufacture of medium-size batches where the workpiece type changes frequently, i e, where component families contain a large number of variants.
Following the principle to always offer its users the best manufacturing solutions, Emag is able to supply other equipment to complement the machining area of the VTC 250 DUO, such as belt grinders for super-finishing operations, deburring spindles, or internal and external cylindrical grinding spindles.
In all cases Emag uses standard components and interfaces, thus offering a way to quickly construct a cost-effective special purpose machine from standard production components.
It ensures that Emag complies with the increasing demands for greater flexibility in the provision of suitable manufacturing solutions.
The extensive application of combined process sequences provides considerable advantages for manufacturers.
A single process sequence on a single machine transforms raw parts into ready-to-install components.
This raises product quality by reducing the number of set-ups.
It also minimises procurement costs and floor space requirements.
In fact, the requirement reduces from several machines - for end working, pre- and finish-turning, turning and milling, deburring of the tooth profile - to just one machine: the VTC 250 DUO.
Cutting speeds and feed rates surpass those of other turning centers and thus reduce cycle times.
The VTC Turning Center can also be used to hard turn.
The sophisticated Emag design makes sure of all this.
Its cornerstone is a sturdy machine base in Mineralit polymer granite with the advantage that its vibration dampening properties are superior to those of grey cast iron.
This allows the machine to work at considerable higher cutting speeds and feed rates and for tools to have a much greater life expectancy.
A fluid-cooling system for main spindle, turrets, electrical cabinet and machine base makes for greater precision.
A twin-circuit heat exchanger maintains the machine temperature within tight limits of the ambient temperature.
Today's demands for flexibility in all in-house operational procedures are met by the construction and assembly of the machine components into a 'hook-up-and-install'-type machine.
In a further development, Emag offers the VTC 315 Vertical Turning Center for the machining of workpieces of 60kg in weight, up to 630mm long and up to 250mm in diameter.
Its main spindle speed is 4000 rev/min.
The 50kW power rating and a torque rate of max.
800Nm make sure that even large components can be machined economically and that manufacturers of primarily heavy shaft-type components too can profit from the extensive application of combined process sequences offered by the VTC from Emag.

The purchase of a Miyano 42mm capacity two spindle, two turret compact turning centre will assist a UK subcontractor in its quest to improve value added content per employee.
At MACH 2006 HS Rowe and Partners of Kingswinford, UK, purchased yet another Miyano machine from Macro CNC. The introduction of the Miyano BNJ-42SY 42mm capacity two spindle, two turret compact turning centre will serve to assist HS Rowe in its quest to improve value added content per employee. The HS Rowe group was initially introduced to Miyano when it acquired Buxton Hays UK, a company that owned five Miyano turning centres.
From this point the relationship extended to the HS Rowe group as it became familiar with the technology and capabilities of the products.
The automotive precision turned parts manufacturer now has seven Miyano turning centres.
Following the purchase of a Miyano BNJ-42S in 2005, the new Miyano BNJ-42SY machine with Y-axis will compliment HS Rowe's current range of fixed head turning centres.
Steven Tyler, director of HS Rowe, commented: 'The BNJ-42S has been a tremendous machine and as part of our philosophy of 'value adding contributions per employee head', the introduction of Miyano machine tools to increase productivity has been instrumental.' Tyler added: 'The new Miyano BNJ-42SY will give us further flexibility and capability as we need to be providing additional capacity in the marketplace.
The Miyano BNJ-42SJ will play a significant part in this.
It will enable us to improve our service to customers, reduce our costs and possibly surpass the excellent product quality we already deliver.' Looking to the future - iIt was in 2004 that Tyler went to Japan with Miyano to start investigating the extensive prototyping and automation technology as adopted in other countries.
Tyler said: 'We looked at the robot loading and gantry systems for complete automation, this technology has not been adopted in the UK as yet and we aim to be at the forefront of technology by introducing these philosophies.' He explained: 'Some of the prototyping machines that Miyano have, particularly in the line of alternatives to sliding head machines are very impressive.
The BNJ range has been excellent, but now they have the multi turret ABX machines to compliment this.
It fills a gap where the Nakamura machines were very large; now the Miyano machines operate at very high speed and produce complex components that fit in well with the direction that HS Rowe is going in.' Tyler said: 'My purpose of visiting the MACH exhibition is to talk about what is going on in Germany, as German manufacturers have been working with automation a lot longer than their UK counterparts.
We will be looking at videos of automated Miyano machines from Germany and hoping to discuss how to implement the technologies in the UK as we are seriously looking to bring in some machines that will further enhance our value added contribution per employee.' He continued: 'We want loading and unloading machines that can run themselves and we want to tap into what is being done in Germany and take this forward.
As a subcontractor it is difficult to make long term commitments but we have to be positive and look at the complex work available and how to implement the technology to guarantee our future with this work - working with Miyano will help us with that.' Following two years of research and market investigation into the available technology, it now appears that HS Rowe is set to commit to automated production as Tyler concluded: 'I feel comfortable working with Macro CNC; this comes from the level of support we receive from the company.
This level of support gives us the confidence to move to the next level and we will undoubtedly have a very successful future working with Macro CNC.'

At a Scottish pipe fittings manufacturer, 10 CNC lathes have replaced two-thirds of the 24 cam-type multi-spindle automatics and all of the company's remaining single-spindle cam autos.
At the Dundee, Scotland, factory of Yorkshire Fittings, two-thirds of the 24 cam-type multi-spindle automatics and all of the remaining single-spindle cam auto's, which once totalled 29, have over the past two years made way for 10 German-built CNC lathes from INDEX. Supplied through UK agent, Geo Kingsbury Machine Tools, at a cost of GBP 3 million, the new machines allow Yorkshire Fitting's pipeline components to be produced economically in one hit, 24/7. The investment followed the acquisition of the former IMI Yorkshire Fittings by the Dutch group, Aalberts Industries, in whose flow control division the company now sits.
Output from the Dundee factory, principally parts turned from brass and gun metal bar, finds its way to the company's headquarters in Leeds, to its Barnsley warehouse, and to a plant in a Budapest, all three centres being responsible for assembly of the firm's products.
Since before the Second World War, the fittings that made the company internationally renowned were of the integral-solder ring type for the plumbing and heating industry.
They were followed some years later by compression fittings.
These two styles are relatively simple to machine, whereas the push-in and press fittings introduced over the past 10 years are much more complicated to manufacture.
It was this increased complexity coupled with a dramatic upturn in production volumes for export markets that in 2003 prompted the Yorkshire Fittings management team to reappraise the production facilities in Dundee.
A local project team headed by planning manager, Barry Stewart, was set up to source new equipment.
Annual output is 15 to 20 million units, giving an indication of the scale of the operation.
Cam automatics are fine for turning simple fittings, and indeed still do, but were unable to produce the more complex types economically, if at all, or to the right quality and consistency.
One of the biggest problems was the production of fittings with multiple bore sizes, as the form drills and reamers needed to produce such fittings on cam machines struggled to hold tolerance.
Single-point CNC turning using standard tooling on modern opposed-spindle lathes was clearly the way forward.
With tolerances fairly open at 0.05 to 0.10mm, practically any make of turning machine could have done the job.
Stewart's prime concern was speed, both of machining and of changeover, as savings in cycle and set-up times have a big impact on profitability in this highly competitive, mass production business.
Some batch sizes are up to 50,000-off, which dictated the continued use of six-spindle bar automatics, but with the flexibility of computer-controlled slides.
There are very few suppliers of CNC multis and Stewart concluded that Index was technologically ahead in terms of the ability to set the spindle speed and feed rates independently at each of the six stations.
Productivity is therefore maximised, as optimal settings can be used and there is no need to compromise the machining parameters at any position.
Two Index MS32C CNC multi-spindle automaticss have been installed in the Dundee plant, the first in 2004.
This set the scene for all of the other turning machine purchases, as it was felt that commonality of machine and control system (Siemens in this instance) was desirable to avoid having to cross-train Yorkshire Fittings' shop floor programmer / setter / operators.
Furthermore, by sourcing all 10 lathes from one vendor, advantageous terms could be negotiated.
Commented Stewart, 'Index is well known for its fast-cycling, high production machines, not only the multi's, but also its twin-spindle, twin-turret bar auto's such as the ABC.' He said: 'We were aware of these machines back in the IMI days, as our Norgren division used them.
They are good, versatile turning centres that are quick to set.' He added: 'So we knew they would be ideal for producing our hundreds of types and sizes of fittings up to 54mm diameter in batches of typically 1000- to 5000-off, but exceptionally up to 10,000- and down to 50-off.' A total of six ABC machines have been installed in Dundee, two of them this year.
Other Index purchases in 2006, apart from the second multi, were a V160G vertical, opposed-spindle lathe for producing large parts, and one of the first C65s in the country.
This novel turning machine consists of an upper turret with XYZ axes capable of working at the main and counter spindles, and a lower, twin XYZ turret.
Both are actuated by sets of kinematic rods behind the slant bed.
That Stewart knew, back in 2004, that such machines with advanced specifications were on the drawing board helped to clinch the business for Index and Geo Kingsbury.
The C65 in particular will be able to improve productivity considerably in the sub-65mm diameter range.
Its ability to tow the opposed spindle synchronously behind back-facing tools on the second, lower turret allows three tools to be in cut simultaneously, a capability normally associated with sliding-head lathes.
Stewart says that some mill-turn cycles on the C65 have been reduced by as much as 25% compared with cutting the same part on a conventional, twin-spindle, twin-turret CNC lathe.
Finally, the V160G offers advanced machining capability for producing large fittings up to 130mm diameter, which are being ordered in much larger quantities since the acquisition by Aalberts Industries.
Turned from billets fed from a dedicated bandsaw, the fittings are somewhat atypical in that they require their flats to be milled, rather than polygon turned as on all the other machines.
The self-loading capability of the hanging spindle, whereby the chuck picks billets sequentially from a conveyor and returns the fully machined component, avoids the expense of having to use a separate handling device, such as a robot or gantry loader.
Concluded Stewart, 'The creation in Dundee of Yorkshire Fittings' centre of excellence for turned parts has had a profound effect on our business.
We now have a lean manufacturing plant able to produce all of our components reliably, repeatedly, in tolerance and economically, ensuring that we will continue to be a world leader at the quality end of the pipework fittings industry.'

Yamazaki Mazak, the world's leading manufacturer of machine tools, will be highlighting its ability to provide a wide cross section of manufacturing companies with the technology to improve their productivity. On the Mazak stand at Manufacturing Technology Ireland 2006 (November 8-9,2006, National Show Centre, Dublin) will be an Integrex 100 ST multi-function machine tool capable of one hit machining. This will be demonstrated alongside a vertical centre Nexus machining centre.

The Integrex 100 ST is ideally suited to deliver Mazak's 'Done in One' machining concept with components machined complete in a single operation.

It is fitted with powerful twin 6000 rev/min spindles that operate in combination with an upper rotary tool, B-axis, spindle (5.5kW) - equipped with automatic toolchange - and a lower, nine-station drum turret to dramatically reduce cycle times.

Mazak's 'Done in One' philosophy can benefit machine tool users across a wide spectrum of industries and company sizes, bringing greater productivity and increased versatility to the manufacturing environment.

Alongside the multi-function capabilities of the Integrex range is the entry-level Nexus range, which comprises machining and turning centres.

The Nexus range provides a cost-effective route to machining a wide range of components in a variety of materials.

Representing the range at Manufacturing Technology Ireland is the VCN510C, a vertical machining centre featuring an 18.5kW, 12 000 rev/min spindle motor for general purpose prismatic machining.

'Yamazaki Mazak has always been at the forefront of multi-function machine development and the concept of Done in One was originated by us.

We are, therefore, extremely pleased that this concept is now being adopted as a viable option by many small- to medium-sized companies.

Our range of machines offers a cost-effective solution to the machining of virtually any component,' said Tony Saunders, Yamazaki Mazak UK's sales director.