A twin turret, twin spindle turning centre has helped an UK aerospace subcontractor to improve its machining productivity by an average of 30%, and up to a staggering 50% on many components.

Helping Rodford Engineering to 'fly high' in the aviation world is a new Miyano BNJ-42SY twin turret, twin spindle turning centre. The new machine has helped the Wimborne, UK- based subcontractor to improve its productivity by an average of 30% and up to a staggering 50% on many components. The second tier aerospace subcontractor manufactures aerospace components for prestigious companies such as Westland Helicopters, Airbus UK and Flight Refuelling of Wimborne.

To gain recognition to work with such companies; Rodford Engineering is ISO 9002 accredited and it has also obtained stringent aerospace certification to supply its customers.

Working with only a handful of customers the majority of the company's work is on fuel systems for the military and Airbus aircraft as well as engine ducting work.

Rodford Engineering's managing director, Rod Dallyn comments: 'We have invested heavily in new equipment in the last three years - buying three mill/turn centres and also replacing older machining centres.

Despite only purchasing the Miyano in September, the BNJ-42SY is likely to have the largest impact of all our machines on the bottom line of the business.' The 13 employee company operates scheduled batch runs with over 100 permanent component types being supplied on a Just in Time (JIT) contract basis.

Operating a JIT system in the aerospace industry puts considerable pressure on Rodford Engineering as Dallyn continues: 'We are under ever increasing cost down pressure from our suppliers and all the while we are expected to absorb the rising material prices.

To combat this, investment in technology is a must.

We recently purchased three mill/turn centres that successfully produce our components to the high standard required by the industry.' He says: 'However, the machines do not have a barfeed and they do not have twin turrets like the Miyano BNJ-42SY.

The barfeed facility allows us to run the machine unmanned leaving the machinist to attend to alternate tasks whilst the twin turret has improved productivity beyond belief.

The Miyano's ability to machine the back of a part with the back spindle and turret whilst the front of the next part is machined on the main spindle has slashed cycle times by 50% on many parts.' When selecting a turning centre, Rodford Engineering specified a machine that could produce complex components and reduce second and third operations.

Rodford also needed a machine with a small footprint and rigidity to comfortably take substantial cuts and produce high surface finishes on the inconel, titanium, stainless steel and aluminium parts the company produces.

'We knew exactly what we needed and the excellent reputation of Miyano for its machines and its service, led us straight to their door.

Another major attraction of the machine is its 42mm capacity and the Fanuc control.

The Fanuc control is the same as all our other machines and this enables us to move staff around.

The Miyano programs are similar if not identical to the current programs, so the training and familiarity period with the machine was very short,' continues Dallyn.

Catering to the company's JIT program, the productivity capability of the Miyano BNJ-42SY now sees the company setting the machine for its average batches of 250 to 1,000 and holding small levels of stock.

This has freed capacity on all the alternate turning centres for short run work.

The short set-ups and the end of manual loading has been a productivity revelation to the aerospace manufacturer.

An example of this productivity can be seen with the company's manufacture of trunnions and threaded bushes.

Rodford previously made significant quantities of both products by using up to four alternate set-ups or machines.

The parts are now manufactured in one hit with a cycle time reduction of over 50%.

Looking to the future Dallyn concludes: 'We are always looking to become more productive and I see twin spindle and twin turret turning centres playing a large part in our future.

Another option for us would be to introduce tool monitoring equipment to enable the Miyano to run throughout the night unmanned.

Latest CNC mill/turn centre with a heavy duty boxway construction sets a new standard in turning and milling operations through the combination of high power and rigidity at both spindles.

The latest SKT 250MS turn/mill centre from Hyundai Kia introduces a 22kW main spindle having a 10in (12in option) chuck with a high capacity 8in chuck subspindle powered by an 11kW drive that is serviced by a 12 position quick-change all-driven 5.5kW motor turret. Adding to the capability of the machine for heavier duty and accurate cutting is its availability in bar feed format with 76mm stock size capacity in the main spindle and 65mm in the subspindle with full C-axis at each spindle to provide a contouring capability. According to UK distributor C Dugard of Hove, Sussex, this latest SKT 250MS with its heavy duty boxway construction, sets a new standard in turning and milling operations through the combination of high power and rigidity at both spindles coupled with high flexibility and features available through the Fanuc 18i-TB, six-axis control.

The 45 deg slant bed of the machine is a single heavy-duty casting with significant ribbing to absorb vibration and a through bore with a large 90mm diameter thermally symmetrical design of headstock.

The machine has a high speed, gearless drive to generate a smoother operation and enables heavy-duty cycles to be performed.

Cutting trials have recorded the machine is capable of maintaining roundness within +0.5 microns and has the ability to achieve a constant cutting accuracy of +3.5 microns.

The capacity is large within a maximum swing of 620 mm and a turning diameter of 410mm by 720mm long.

Travel in the X-axis is 290mm, Z-axis is 750mm and B-axis is 700mm with rapid traverse rates of 20m/min in X and B and 24m/min in Z.

Reflecting the capacity of the machine, the main spindle has a maximum speed of 3,500 rev/min and the subspindle 4,000 rev/min while the high performance AC servo driven turret, with a very rigid three-piece 5.560kgf coupling, has an indexing time of 0.3s/position.

The maximum speed of the driven tools is 4,000 rev/min powered by 5.5kW motor able to accommodate tool shank sizes up to 20mm diameter and rigid tap up to M16 thread size.

Included in the specification is the well-proven Q-setter for automatic determination of tool offsets, that eliminates the need for trial cuts, measurement and offset input.

Options include a parts-catcher for bar feed applications, high pressure coolant and swarf management.

Automatic work co-ordinate setting is available through direct input of depth-of-cut at the Fanuc control.

Leading a range of advanced CNC turning centres at MACH will be a seven-axis 'lights-out' chucking orientated turning cell with the a patented, fully integrated autoload and unload system.

Seven-axis turning centre has integrated handling Leading a range of advanced CNC turning centres at MACH will be a seven-axis 'lights-out' chucking orientated turning cell with the a patented, fully integrated autoload and unload system. A Colchester Tornado with seven axes heads up a count-down of six, three and two-axis machines providing a totally new level of productive capability solutions for multi-axis turning machines at affordable prices. The new machines, featured on the Colchester Lathe stand at MACH 2006 will depict the re-generation of this top-selling Tornado marque to global markets.

And, with the latest development of the machine range, the exhibition will become the platform to portray the move into turnkey project engineered solutions for the Heckmondwike, West Yorks based machine tool builder.

Complementing the Tornado, Combi and MultiTurn machine ranges on show, the Colchestersales (UK) operation with technical centres in the Heckmondwike headquarters, at the 600 Centre in Shepshed, Loughborough and at RK International in Erith, Kent, will also be demonstrating the latest Richmond range of vertical machining centres that strengthens the 'package' solution provider operation now available from this single source.

Leading the Tornado range at MACH will be the seven-axis T6MS 'Lights-out' chucking orientated turning cell with the Colchester patented APL 5000 fully integrated autoload and unload system.

This new machine concept has a new level of flexibility gained from the latest Fanuc control to work in unmanned installations in conjunction with customer specified material handling systems such as part stockers, carousel palletising or conveyor systems.

T8MSY is the latest Tornado development with a specification that includes a subspindle to incorporate second operation cycles, a Y-axis cross feed to the 12 station all-driven turn and mill turret and the well-proven 'lights-out' bar package of swarf conveyor, Renishaw probing, tool monitoring and work scheduling software.

Alongside the Tornado range will be the powerful Combi 6000 heavy duty combination lathe series that is currently reaping outstanding success with the oil and gas industry due to its 170mm hollow mandrel, swing capacity and high levels of versatility and flexibility from programming and control functionality.

The latest version of Colchester MultiTurn is also due for launch at MACH 2006 with newly upgraded Fanuc OiTC with Manual Guide i programming software.

To date, this machine has won considerable acclaim and international sales based on a market trend-setting price that is very competitive for its offering of high levels of flexibility and capability.

Multi-tasking CNC mill/turn centre has the ability to fully utilise 3D-CAD, offers utilisation of linear guides in all axes and allows 0.0001 degree increments to be programmed on the B- and C-axis.

Yamazaki Mazak's Integrex range, the most widely sold multi-tasking machine tools in the world, epitomise the Done in One concept, with components machined complete in a single set-up. Now, with the introduction of the Integrex Series IV, this concept is further advanced. The fourth generation Integrex series provides the user with a powerful multi-tasking machine tool platform from which to make full use of the machining flexibility that Yamazaki Mazak has created.

One of the key developments on the series IV Integrex machines is the introduction of the Mazatrol Matrix control.

It is this new CNC system that enhances the capabilities of the machine and the interface between it and the operator and/or remote production management and control.

Features such as Intelligent Safety Shield would not be possible without the development of the Matrix control system.

Typical of the range is the all-new Integrex 300-IV ST, which makes its UK exhibition debut at MACH 2006.

Key among the developments of the series IV Integrex is the ability to fully utilise 3D-CAD, utilisation of linear guides in all axes, and 0.0001 deg increments on the B- and C-axis.

This, when combined with the exceptional rigidity of the machine design, results in even better positional accuracy.

The Integrex 300-IV to be displayed at MACH features opposed spindles and a lower turret with driven tool capability, capable of working on either spindle.

Using the lower turret and upper tool station simultaneously for balanced cutting greatly reduces cycle times, improves turning accuracy and delivers higher quality in terms of surface finish.

Additionally, thanks to the innovative design of the lower turret, the same tool can be used to machine components located in either of the two spindles.

This reduces the total number of tools required, reducing tool costs and improving productivity.

Other developments across the Integrex range include Intelligent Thermal Shield, Intelligent Safety Shield and Active Vibration Control.

Intelligent Thermal Shield has been developed to minimise heat displacement, the machine units producing the minimum possible amount of heat during operation.

Additionally, there is automatic compensation for changes in room temperature.

As a result, machine heat displacement is less than 10 micron with a room temperature change of 8 deg C.

Intelligent Safety Shield highlights any possible collision points when any program is simulated on-screen prior to it being used to actually machine components.

However, Intelligent Safety Shield takes this protection several steps further with the machine being monitored when it is operated in manual mode for instance, during tool measurement with the Tool Eye or when changing inserts.

All machine movements are monitored by the Mazatrol MATRIX control, which moves the machine's 3D model simultaneously with the manual data inputs to check machine interference.

Should this occur, the axis movements are stopped immediately, preventing damage to the machine and avoiding costly downtime.

The third innovation is Active Vibration Control, which reduces vibration in all axes during rapid accelerations and results in improved accuracy and surface finishes.

The main specifications of the Integrex 300-IV are a maximum machining diameter of 760mm; maximum machining length of 1524mm; 26kW, 4000 rev/min turning spindles; 18.5kW, 12 000 rev/min milling spindle; and rapid traverses of 38m/min in X/ Z and 26m/min in Y, with a maximum C-axis rotation speed of 555 rev/min.

In multi-function, multi-facet machining, the concepts now benefit from the latest CNC that enhances machine tool capabilities and the interface with the operator and/or production management.

Yamazaki Mazak's Integrex range is one of the most efficient methods of producing complex components in a single set-up. With the Integrex e-range Yamazaki Mazak has taken this concept to the next level by fusing Information Technology with Manufacturing Technology to deliver multi-tasking machines ideally suited to the machining of large workpieces. The Integrex series provides the user with a powerful multi-tasking machine tool platform from which to make full use of the machining flexibility that Yamazaki Mazak has created.

One of the key developments is the introduction of the Mazatrol Matrix control.

It is this new CNC system that enhances the capabilities of the machine and the interface between it and the operator and/or remote production management and control.

Features such as Intelligent Safety Shield would not be possible without the development of the Matrix control system.

Typical of the e-tower range is the new Integrex e-800V/5.

Designed for turning and milling large diameter workpieces on multiple faces, the e-800 makes full use of the tilting spindle and rotary table technology pioneered by Yamazaki Mazak.

The e-800V/5's powerful 22kW milling spindle can be positioned to provide vertical or horizontal milling capability; alternatively, it can be moved to any position within a 150 deg arc.

When used in conjunction with the 30kW rotary table, multi-facet machining becomes a straightforward proposition.

Components measuring up to 730mm wide by 1000mm high can be machined on five faces whether they require milling, drilling, turning or a host of other machining processes.

Differentiating the e-machines from the conventional Integrex is the addition of innovative functions to support multi-tasking machining.

This includes integrated factory management functions such as programming, material and tool stock control, remote alarm notification, maintenance information and scheduling, production control alarm, and generating production reports.

All of these functions can be used independently or as part of an advanced manufacturing cell using Yamazaki Mazak's Cyber Factory model.

Other developments across the Integrex range include Intelligent Thermal Shield, Intelligent Safety Shield and Active Vibration Control.

Intelligent Thermal Shield has been developed to minimise heat displacement, the machine units producing the minimum possible amount of heat during operation.

Additionally, there is automatic compensation for changes in room temperature.

As a result, machine heat displacement is less than 10 micron with a room temperature change of 8 deg C.

Intelligent Safety Shield highlights any possible collision points when any program is simulated on-screen prior to it being used to actually machine components.

However, Intelligent Safety Shield takes this protection several steps further with the machine being monitored when it is operated in manual mode for instance, during tool measurement with the Tool Eye or when changing inserts.

All machine movements are monitored by the Mazatrol MATRIX control, which moves the machine's 3D model simultaneously with the manual data inputs to check machine interference.

Should this occur, the axis movements are stopped immediately, preventing damage to the machine and avoiding costly downtime.

The third innovation is Active Vibration Control, which reduces vibration in all axes and results in improved accuracy and surface finishes.

Multi-tasking mill/turn centre designed for medium-sized batch size production has three tooling turrets, two main spindles and performs simultaneous 4-axis machining.

The latest addition to the Yamazaki Mazak Multiplex multi-tasking family of machines, the Multiplex 3 8200Y, further adds to the company's philosophy of developing technology with a purpose. Designed for medium-sized batch size production the Multiplex 3 8200Y benefits from the addition of a lower turret. This, when used in combination with the machine's two spindles and twin upper turrets, provides an extensive capability for simultaneous four-axis machining.

The lower turret, like the two upper turrets, is suitable for fixed and live tooling, giving users even more options when it comes to reducing cycle times by completing as many operations as possible in a single set-up.

The identical horizontally opposed spindles both have outputs of 22kW and generate 35.7 kgf.m of torque and top speeds of 5000 rev/min.

Each has a C-axis and these highly-stable spindle units lend themselves to high speed, high productivity machining.

Aiding these productivity gains is the inherent agility of the Multiplex 3 8200Y.

Rapid feedrate is 50m/min in the X1, X2, Z1 and Z2 axes reducing to 38m/min for the X3 and Z3 axes; 20m/min for the two Y axes, while the two C-axes can run at 400 rev/min.

Acceleration/deceleration in the X and Y axes is 1G.

To maximise utilisation the Multiplex 3 8200Y can be equipped with optional gantry loading or barfeeding.

Alternative enhanced productivity systems such as cut-feeder and shaft loading/unloading systems are also available as options.

Powerful 37kW turning centre has a maximum machining diameter of 860mm and is also equipped with a powerful, 11kW, 3000 rev/min milling spindle.

Yamazaki Mazak's CyberTech Turn 4500M will make its UK debut on Stand 5120 at MACH 2006. This powerful turning centre has a maximum machining diameter of 860mm and, depending on which bed length is specified, a maximum machining length of 3048mm. Heavy-duty machining capability is provided by a main spindle unit with a 37kW/2400 rev/min capability that delivers a staggering 326.3 kgf.m (2360 ft.lb) of torque.

The CT4500M is more than just a turning machine, though, and is also equipped with a powerful, 11kW, 3000 rev/min milling spindle.

The resulting turning centre is the ideal solution for those companies with a requirement to machine long, large diameter components, typical of those found in the aerospace and oil industries.

The large turret of the CT4500M has capacity for twelve, 32mm square shank tools and can also accommodate boring bars with shanks up to 50mm diameter.

A further plus point is the fact that rotary tools can be located in any of the turret positions and productivity is boosted by the use of random, shortest path, non-lift indexing, which is achieved in a time of 0.4s.

Additionally, two boring bars with 80mm diameter shanks and up to 1m in length can be located in the boring bar stocker.

This feature facilitates the machining of deep bores without the need for time-consuming manual intervention.

For shaft work a servo-driven tailstock, with a stroke up to 2550mm, simplifies set-up as its position is recognised by the Mazatrol 640MT Pro CNC, and both its position and thrust settings are controlled by M-code functions.

For further workpiece support automatic programmable travelling steady rests are available.

Furthermore the CT4500M comes with a choice of spindle bore diameter.

As standard, the machine has a 132mm bore and options are available for 185mm, 275mm and 320mm if required, with either a 305mm or 381mm bore through the chuck.

Finally, for a machine of this size agility has not been compromised and rapid traverse rates in the X and Z axes are 24m/min and 30m/min respectively.

The contouring capability, so often required on aircraft and oil industry components, is enhanced by the C-axis, which has a minimum programming increment of 0.001 deg.

Other machines in the CyberTech Turn range offer variations such as the addition of a lower turret or, in the case of the entry-level CT4500 supplied without a milling spindle.

A compact universal turning centre for processing chuck and bar work offers everything: C-axis, powered tools, powerful digital drives and a choice of fully equipped CNC systems.

Design to Cost is Emco's motto for the launch of its new high class turning centre, now available at an amazingly competitive price in the 45mm bar capacity market. A top European product, made in Austria, it meets every challenge expected of a 'State of the Art' lathe. A machine that brings together the highest European quality with a very low price, to produce high-precision parts at unbeatably low piece part prices.

An honest machine, with high customer value.

* Design to cost as the guiding principle - low cost with the highest performance is not just a slogan with this machine.

Emco's design department has made it a reality.

Back in mid- 2004, we started developing a whole new generation of machines.

The 'Design to Cost' principle was the highest maxim for this development work.

Increasing production efficiency as much as possible was the highest priority from the beginning.

At the same time, all the components that provide the performance, precision, and long life of the machine were kept and improved upon wherever possible.

* Finest machine construction - the Emco development engineers and production group have done their jobs well.

The first impressive result was the very successful Emcoturn E65 CNC turning centre, which now has a little sister in the E45.

The E45 replaces the Emcoturn 345 in the Emco portfolio.

It is a compact universal turning centre for processing chuck and bar work.

Just as its predecessor, this machine offers everything that a good turning centre should these days: C-axis, powered tools, powerful digital drives and a choice of fully equipped Siemens or Fanuc controls.

Emco promises the finest workmanship, down to the last screw, 'Made in Austria' - for high precision parts and long machine life.

Nigel Bunt, joint managing director, Said 'This further development of the 'E' line of turning centres provides a range of entry models for our customers'.

'It now means that we can cover all of our customers turning needs from EMCO, with the competitively priced 'E' range of machines through to the multi axis mill-turn machines and fully automated solutions.' * About HK Technologies - HK Technologies is a leading provider of machine tools and offers the latest technological products and solutions to the manufacturing industry.

We are located in Rugby in the United Kingdom and manufacture laser marking machines for home and export markets.

In addition we represent some of the worlds market leading companies and offer these products to UK Manufacturing.

We supply manufacturing solutions in a number of industries including the following: aerospace, automotive, general engineering, medical, marine, jewellery, mould and die, rapid prototyping and styling.

Adding a Y-axis onto a range of vertical turning lathes has given them machining centre-type production capabilities for a wide range of prismatic components up to 50 tonnes.

The addition of a Y-axis for the new Toshulin Powerturn Y range of vertical turning lathes (VTLs) available exclusively in the UK from Ward CNC has transformed the Czech-manufactured high-precision vertical boring and turning workhorses. They now have machining centre-type production capabilities for a wide range of prismatic components weighing up to an incredible 50,000kg. Of similar highly-rigid build characteristics that have enabled Toshulin to supply Powerturns to users in 58 countries worldwide, the new Powerturn Y is available in six size variants with table diameters from 1250 mm to 4000mm.

The machine's Y-axis capability is courtesy of a high-accuracy sliding table system based on linear rolling profile guideways driven by servo drive and ballscrew.

The Y-axis provides a travel of +/-900mm on the smallest machine in the range up to 2700mm on the largest machine, to complement the machines' capability for processing workpieces from 1400 mm to 5000 mm diameter (for facing and peripheral turning) and within the Z axis stroke of 1280mm (optionally 1500mm).

Ram cross section across the range is 240mm by 240mm, and all machines feature a third CNC axis (C-axis) and a live spindle drive.

The machines can be equipped with various types of toolholders, from conventional 40 by 40-tool ATCs through to automatic tool exchange for Sandvik or Kennametal turning systems, as well as a rotary B-axis and milling head for drilling and milling, and horizontal milling with the turning tool drive, respectively.

In addition, a numerous number of standard/optional features further improve the flexibility of the Powerturn Y, including three-, four- and six-jaw hydraulic/mechanical chuck, a rotary grinding wheel dressing (for straight or profile grinding), high-/low-pressure tool coolant, in-process workpiece and tool checking, tool monitoring and identification systems, as well as workpiece exchange system.

Six-axis, 'lights out' mill/turn centre package will demonstrate unmanned orbital milling, off-centre drilling and tapping, the machining of hexagons and engraving .

An unmanned demonstration of orbital milling, off-centre drilling and tapping, the machining of hexagons and engraving will be performed on the latest six-axis Colchester Lathe Tornado T8MSY specified with the 'Lights-out' package from Colchestersales (UK). The machining operations will show the advantages gained with the latest +40mm of Y-axis cross-feed to the 12 station all-driven turret of the Tornado as part of the popular 'Lights-out' unmanned production package. Demonstrated on stand 5334 at MACH 2006, the 54mm bar capacity Tornado T8MSY with subspindle will be portraying 'one-hit' cycles where it is capable of heavy duty milling and drilling through its 12-station Sauter 3.7kW, 5,000 rev/min power tool turret.

The turret is able to accommodate tooling having a shank size up to 20mm diameter and through the Y-axis, machine up to +/-40mm - either side of centre line.

The 'Lights-out' package is the flagship of the Tornado range enabling highly automated cycles to be performed utilising the MBF 1000 integrated barfeed, parts-catcher, swarf conveyor, on-board Renishaw probing, axis tool monitoring with sister tool replacement and on-machine production scheduling software.

The machine has a 22kW main spindle with options of 3,500 or 5,000 rev/min drive and a 7.5kW, 6,000 rev/min sub-spindle.

It has a fully programmable B-axis with synchronised part transfer to create 'single hit' combined operation production cycles.

Chuck size is 254mm or 210mm and bar capacity 66mm diameter with a maximum turning diameter of 260mm by 500mm turned length.

Of major importance to its high metal removal capability is the rigidity of the turn/mill platform created through the patented 'Duo-Stable' advanced construction techniques employed by Colchester Lathe which integrates a stocky, low profile cast iron bed with a polymer concrete filled machine base.

Together this technology is some 300% more effective than a conventional cast iron frame.

This construction also provides vastly improved thermal characteristics giving far more consistent machining cycles.

Low cost, 'entry level', XYZ Mini Turn 200 turning centre has been designed on the basis of machining a wide range of components within the smallest possible amount of space.

Low cost, 'entry level', XYZ Mini Turn 200 turning centre has been designed on the basis of machining a wide range of components within the smallest possible amount of space. The new low cost, entry level, XYZ Mini Turn 200 turning centre has been designed on the basis of machining a wide range of components within the smallest possible amount of space. Although it is the smallest model in XYZ Machine Tools' range of turning centres, the 15kW, 4000 rev/min XYZ Mini Turn 200 is capable of a 200mm maximum turned diameter and has a maximum swing of 400mm.

It also features a 56mm spindle bore, with a 42mm drawtube capacity, to accommodate oversize bar.

Axis travels are 155mm (X) and 510mm (Y), with rapid traverse rates of 12 and 14m/min, respectively.

Distance between centres is 500mm and the XYZ Mini Turn 200 is equipped with an 8-station turret that holds 40mm diameter boring bars and turning tools with a 20mm by 20mm shank.

Occupying a space-saving 2700mm (W) by 1670mm (D) by 1800mm (H), the XYZ Mini Turn 200 is equipped as standard with a 200mm three-jaw hydraulic chuck, flood coolant and Siemens 810D conversational Shopturn CNC.

Rigidity and vibration absorption is guaranteed by the Meehanite cast iron construction, with the machine weighing in at 4200kg, and auto lubricated hardened and ground slideways ensure smooth axes travel, minimum wear and a high quality surface finish for the machined component.

Offering a host of canned cycles, the Siemens 810D Shopturn control makes shopfloor programming fast and simple, involving the minimum of keystrokes and the maximum reassurance to the less experienced operator.

Available as a standard, very cost-effective ready-to-run package, a 7-axis turn/mill chucking cell has an integrated programmable automatic loading and unloading system.

Available as a standard, very cost-effective ready-to-run package, the 7-axis Colchester Tornado T6MS turn/mill chucking cell with a fully integrated programmable APL 5000 automatic loading and unloading system will be demonstrated on stand 5334 at MACH 2006. Available through Colchestersales (UK) of Heckmondwike, UK, the Tornado T6MS with APL 5000 is a true fully integrated cell that is able to combine first and subsequent turning and milling cycles in a 'lights-out' environment with its part handling automation able to 'handshake' with customer supplied conveyors, pallet stockers and carousel type units. Most important with this new Colchester chucking lathe development is that the system is self-contained within the machine guarding and does not require additional fencing and safety areas normally mandatory for robotic based systems.

The cell has been devised for maximum spindle uptime and machine utilisation with the main and subspindle of the Tornado T6MS able to exchange the component using 'kissing' spindle techniques to enable first and second operations to be combined into a single cycle.

Here the APL 5000 feeds the work to the main spindle of the machine and retrieves the completed part from the subspindle and will only add between six and eight seconds to the normal production cycle.

This is a far more cost-effective solution to achieve a consistent cycle that could ever be matched by an operator, especially with forgings, castings or billets up to 80mm diameter by 100mm long and weighing up to 5kg.

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

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

Powered via ballscrew and servo drives, a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems Whatever type of material or work handling system is connected, the machine is able to manipulate raw material supply to the main spindle and accept the off-load of completed parts from the main or subspindle enabling the production cycle to continue independent of the loading system.

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

The Tornado T6MS has a 440mm swing over bed and 220mm maximum turned diameter by 450mm long with a 54mm bar capacity and options of 170mm or 210mm chuck size.

The subspindle chuck size is 130mm.

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

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

The machine can be fitted with Renishaw probing for in-cycle qualification with feed-back correction to the control and torque-based tool monitoring; sister tool replenishment is also available.

Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that provides some 300% improvement in stability over conventional cast iron.

This system uses an encapsulated polymer concrete base fill to which is mounted a compact cast iron bed that will minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.

A compact vertical turning machine that comprises high technology components, maximum flexibility and uncompromising precision is being offered at an attractive price.

On show at MACH for the first time on stand 5330 will be the new BlueTurn range of vertical turning centres from Cincinnati. At MACH 2006 will be the BlueTurn 250; a compact vertical turning machine that comprises high technology components, maximum flexibility and uncompromising precision at an attractive price that makes this vertical turning range an exceptional price and performance package. The BlueTurn range of machines is a machine tool concept that focuses upon productivity and change-over times, an important cost factor in small and medium-batch production.

With unlimited accessibility to the working area via a large protection door that opens over its full height and a large viewing window for optimum visibility; the BlueTurn 250 opitimises user friendliness.

Swarf management is optimised by the very nature of the vertical turning concept.

The part is held vertically and machined from underneath, to ensure the swarf falls away from the part and into the removal system below.

Air flushing in the work area is also supplied as standard for further enhanced swarf removal.

The smallest machine in the Cincinnati BlueTurn range, the BlueTurn 250 has a optional component conveyor system that can accommodate three frame sizes from 50-250mm part diameter.

In increments that range from 50-80mm, 80-130mm and 130-250mm with a 20kg maximum single component weight capacity, the BlueTurn is ideal for anything from small batches to longer production runs.

The component conveyor system provides a productivity advantage allowing unmanned running and minimal operator intervention.

The tool turret supports 12 tool positions with a safe and solid tool interface that is bi-directional and hydraulically sealed.

The tool positions can accommodate driven tooling and its electric rotation system guarantees extremely short indexing times to minimise tool to tool times.

The compact synchronous motorised spindle has an automatic loading and unloading function that guarantees exact positioning by means of the C-axis.

This works in harmony with a direct digital axis drive that has an X-axis rapid traverse of up to 60m/min and a Z-axis rapid traverse of 30m/min with an acceleration of 4-6m/s2 to further enhance productivity and maximise spindle utilisation.

With user friendliness and simplicity being key design elements of the BlueTurn range, the 'chuck change over assist' feature ensures the chuck can be taken out of the working area with minimum effort.

To assist changeovers the spindle is traversed to a spring loaded plate that makes crane access possible and problem-free.

To further enhance the user friendly experience, the optimised control and drive package is available with either the GE Fanuc 21i-TB or the Siemens Sinumerik 840D control system.

These innovative packages provide the user with shopfloor programming as standard for added flexibility.

All this is built on a machine bed that has extremely high rigidity guaranteed by an extensively ribbed, undivided casting design with high damping quality.

The bed has optimum support on vibration-damped levelling elements and a tub construction designed to avoid leaks.

This ensures a high level of rigidity that will deliver excellent surface finishes and minimised vibration when undertaking heavy cutting operations.

With productivity a main focal point, a chip conveyor is an optional extra.

The BlueTurn chip conveyor provides good accessibility to the level indicator plus a pump and cartridge filter that are simple to maintain.

The BlueTurn 250 on show at MACH is equipped with the Siemens Sinumerik 840D CNC control with Shopturn shop floor programming as standard.

Through the use of the optional parts conveyor and swarf conveyor it will demonstrate unmanned running and minimal operator intervention.

Also available from Cincinnati is the similarly designed but larger BlueTurn 450.

The CNC-controlled closed loop conveyor BlueTurn 450 also has three frame sizes like the BlueTurn 250.

The BlueTurn 450 can accommodate components from 130mm to 450mm diameter with its three frame sizes of 130-250mm, 250-350mm and 350-450mm.

With a 30kg maximum single component weight, the BlueTurn 450 is designed for larger components.

The inverted spindle travelling column design of vertical turning lathes provides a self-loading cycle and two machines can be installed side by side to handshake and reposition the part.

Creating a very simple solution to unmanned turn/mill cycles, the inverted spindle travelling column design of vertical turning lathes from Hyundai-Kia in the SKT 21 VM provides a self-loading cycle whereby the machine spindle picks up and deposits components from an integrated pallet-based stocker. Such is the configuration of the system that two machines can be installed side by side to handshake and reposition the part to provide first and second operation turn/mill cycles with the integrated loading stocker and unload stocker respectively sited at each end of the cell. The SKT 21 VM is one of the latest high specification and quality machine tool solutions now available through C Dugard of Hove, Sussex, under the banner of Hyundai-Kia Machine, Korea's largest by some significant margin machine tool company.

The machine is the most recent from the machine tool division of the $2.8 billion Hyundai-Kia Automotive Group that is creating high productivity solutions from the production engineering requirements of its parent and its subcontract part suppliers from around the world.

Here, the self-loading cell-based turn/mill technology was high on the development agenda.

Having a maximum turning diameter of 250mm by 150mm long, this 8in chuck size machine has a 12 station, servo-driven turret with each position able to accept live tools powered by a 3.7kW, 4,000 rev/min motor.

Live tool capacity is 20mm and M16 for threading tasks.

Turret indexing time is 0.3s via a three-piece coupling unit having a hydraulic clamping force of some 43kN (4.3 tonf) to provide a high rigidity cutting unit.

The built-in spindle has an 11kW motor giving 30 to 5,000 rev/min with a 0.001 deg C-axis controlled from the Fanuc Oi-T unit.

A high accuracy specification of +3.5 microns and roundness capability within +0.5 microns is achieved from the combination of the quality build specification that includes a thermally symmetrical headstock, square box-type ways set on a cast iron bed able to absorb vibration and maintain control over thermal distortion.

With rapid traverse rates of 30m/min, the travelling column spindle arrangement is able to deposit the completed part and pick-up the next component from the stocker unit in order to maintain high levels of overall machine utilisation.

There are two types of stocker available with eight or 12 pallet options.

Each pallet has three adjustable guide posts for internal or external part support and a rotating common cam mechanism that automatically centres the component ready for the inverted machine spindle to perform a clean pick-up.

With the inverted spindle configuration, swarf control is excellent using high slant angle bed covers that funnel the chips directly into a central conveyor.

This enables swarf to quickly exit the working area without influencing the thermal characteristics of the machine.