Modular CNC mill-turn centre that takes two to four tooling turrets and can cut with four tools simultaneously can now be specified for 80mm bar capacity.

The Turn Mill Center TNX80/65 with its up to four tool carriers already set new standards for high-performance machining last year. A unique feature of this machine is the modular design of the two turrets - and even three or four turrets are possible. Thus each tool carrier can have its own Y-axis.

This, in turn, permits that up to four tools work completely autonomously without interfering with each other.

And this means that the TNX80/65 can achieve almost the same cycle times that have so far only been possible with multi spindle machines.

A profitable advantage is the possibility that the tool carriers can be freely assigned to the two spindles.

At the EMO 2005, the TNX80/65 was presented for the first time with an increased bar capacity from 65 mm to 80 mm.

This also means an extension of the performance parameters.

Another unique feature is the new vertical tool carrier.

This is an upright 4-side turret with a 360 deg B-axis.

There are two tool holders on each side.

While four holders are designed as milling spindles with a torque of up to 74Nm, the focus of the other stations is on high speeds of 6000 rev/min.

Of course, it is also possible to operate the counter spindle with the vertical turret.

The TNX80/65 is a highly complex turn mill center - this is also demonstrated by the powerful tool drives at the turrets with VDI40 tool holders.

For reasons of productivity, Traub has deliberately decided to do without a tool changer.

All tools are already available in the working area, which reduces the idle times to a considerable extent.

In summary, the cycle times can e g, be reduced by up to 3 minutes with an equipment of 55 tools and a chip-to-chip time of 1.2s from cutter to cutter can be reached - even in the most unfavorable case.

Milling with a torque of up to 74Nm - up to now, these values have only been achieved with milling or machining centers.

Another advantage is the possibility of 6-side machining even in angular positions.

The features of the TNX80/65 at one glance: * Extended range of workpieces because of an increased bar capacity from 65mm to 80mm.

* Modular design of the two turrets, optionally three or even four turrets possible.

* Each tool carrier can have its own Y-axis.

* Upright four-side turret with a 360 deg B-axis, on each side two tool holders, i e, a total of 8 tool holders

The latest version of a 64-bit CNC on Traub mill-turn centres allows the cycle times to be be reduced and programming, optimisation or a 2D simulation can be made in dialog or NC.

Traub says that its successful mill-turning centres have now higher NC performance The mill-turn centres have a 12-station disk-type turret with VDI40 shank, extremely high degree of collision-free working due to a turret clearance of 420mm and an optional Y-axis. These are the features of Traub's 'tried and tested' concept of the TNA400 universal turning machines. The tailstock is part of the basic equipment; it can be manually positioned on the separate guideway and is operated hydraulically.

The major advantage offered by this concept, however, is still its working area: The travel of the X-axis is very high.

This makes it possible to have the X-way moving up to 50mm below center in case of milling processes or hole patterns.

This corresponds to the travel of the Y-axis in both directions.

Thus, it is possible to work very precisely without a C-axis in the applications mentioned above.

The main drive with the tried and tested belt spindle produces a torque of up to 485Nm.

The very high positioning accuracy of the C-axis is achieved by the direct travel measuring system which is part of the standard equipment.

Besides the short taper mounting A6, Traub now offers also the A8 type according to DIN55026 as a new feature.

But the absolute highlight is set by the 64-bit control TX8i in its most recent version which has been entirely developed by ourselves and which is now also offered for turning machines TNA300, TNA400 as well as for the turn mill center TNC42/65.

The latest version of the 64-bit control TX8i With this new control system, the cycle times can be reduced to a considerable extent by an even higher CNC performance - that is Traub's commitment to their customers.

As against the TX8H, the PLC cycle time is reduced by factor of four, the block change times are reduced by 50% from 28ms to 14ms, the block calculation time can be reduced by 30 % and the macro calculation time even by up to 100 %.

A decisive and thus very significant advantage offered by the TX8i is the possibility of interactive programming - in dialog as well as on NC basis.

This means that programming, optimization or a 2D simulation can either be made in dialog or on NC basis.

On his way to the first good workpiece, the user is guided by the control system with graphical, object-oriented dialogs, which minimises the possibility of errors occurring and leads to a significant reduction of set-up times.

While producing the required safety is provided by a very sensitive tool breakage and tear monitoring system on the basis of current measurements on the axis motors.

This monitoring is integrated into the control system.

When several tools are working, each of them can be monitored simultaneously.

The TX8i Control is compatible with all previous Traub control systems.

Electronic handwheel In connection with the TX8i Control and with TNA300, TNA400 as well as with TNC42/65, Traub now offers also an electronic handwheel for starting up the programs.

This does not only put the user back into the good old times but also turns out to be very useful, especially at extremely complex program positions.

So it is possible to switch from automatic operation to the handwheel mode and each turret can be moved manually within the CNC program according to the programmed contour.

* Automatic tool control (ATC) - one of Traub's 'hallmarks' is still the Automatic Tool Control (ATC).

ATC is an instrument for measuring tools in the machine quickly and completely.

For this purpose, the tool is positioned under an optical crosshair, an acknowledgement key is pressed and the tool data are directly transmitted to the control system.

* The advantages offered by the TNA400 at a glance - 12-station disk-type turret with VDI40 shank - high degree of collision-free working due to a turret clearance of 420mm - profile or hole pattern machining without moving the C-axis, since the X-axis - moves up to 50mm below center and this corresponds to the travel of the Y-axis of +/- 50mm - high torque of up to 485Nm - high accuracy of the C-axis due to a direct travel measuring system.

* Arguments in favor of the 64-bit control TX8i - reduced set-up times due to higher NC performance - interactive programming, optimisation and simulation in dialog or in NC mode possible - prevents errors and reduces set-up times due to its object-based dialogs - sensitive tool breakage and wear monitoring system - compatible with all previous Traub control systems - high availability, cost reduction since machine, control and drive are provided by one single source

Pick-up spindle, 5-axis, vertical turning and machining centre combines operations into one set-up and reduces quite considerably the work-in-progress of medium batches.

The VLC 400 MT shortens production throughput times. The turning and machining center utilises the pick-up principle to load and unload itself. It turns, mills, drills, reams and grinds rotationsymmetric workpieces of up to 420mm diameter and cubic components of up to 300mm A/F, cuts threads and in-process gauges the workpieces.

Where it previously required a number of workstations, the 5-axis machine delivers a finished precision product.

Typical examples are round and not so round steel components and castings from the automotive and mechanical engineering industries.

The VLC 400 MT Turning and Machining Center reduces quite considerably the work-in-progress (production inventory) in the manufacture of medium batches.

Typical workpieces are pump housings and similar components of up to 420mm diameter or 300mm A/F.

Batch sizes of 20 to 100 are ideal.

The multi-functional machine loads the raw-parts, machines them and unloads them in ready-to-install condition.

Unlike the majority of competitive systems, the VLC 400 MT reduces the complete-machining process, the functional capacity utilisation and the economic viability to a common denominator.

As its workhandling equipment is based on the pick-up principle, the machine has really been automated from the day of its conception.

Tool changes are carried out concurrent with the cycle time.

Even resetting the machine to differently shaped and dimensioned workpieces is quick.

The VLC 400 MT offers the user further advantages, such as: * Complete-machining in a single set-up, thus guaranteeing contour integrity as well as dimensional and positional accuracy .

* linear drive technology and a solid C-block machine construction that ensure an excellent, constantly maintained surface finish.

* Shorter tool change travels that bring about a reduction in idle times.

* The arrangement of sensitive components and guideways outside the machining area, with no danger of contamination, which brings operational reliability.

* As the machine is constructed at right angles to the material flow, transfers are possible.

* In case of a rapidly changing component spectrum the initial investment remains protected.

Technical and economic details - the VLC 400 MT completely-machines ready-to-install, cubic raw-parts up to 300mm x 300mm x 300mm, as well as rotation-symmetric components of up to 420mm diameter, at five degrees of freedom, using NC axes X, Y, Z, B and C.

The materials that can be machined are - structural steels and tool steels (in exceptional cases up to 62 HRC) - high-alloy materials - grey cast iron, cast steel and light-alloy castings, as well as - light alloys and non-ferrous metals.

The following processes are considered standard: turning - milling - deep-hole drilling - reaming - grinding - threading and - in-process gauging.

Typical workpieces are round, not so round and cubic components as used by - automotive industry and motor construction - fluid technology - building, agricultural and harvesting machinery, - mechanical engineering industry and the aircraft industry.

Economical batches are - job lots - medium batches of, for instance, between 20 and 100.

* Structural details - the X-axis of the VLC 400 MT lies at right angles.

X-, Z- and C-axis are at the top, Y- and B-axis at the bottom.

The tool magazine is at the front, with the turret approaching horizontally.

Owing to its position, the magazine - for example a chain magazine with 24 positions - is considerably easier to access than others that are loaded from the back of the machine.

The VLC 400 MT is mounted on a patented mono-bloc base in Mineralit, the top part of which carries the compound slide, while the bottom part carries the milling unit with Y- and swivel axes.

To increase track pitch, the guideways are arranged diagonally.

Based on this design, the compound slide for the Z-axis also features two guideways.

Instant operational effects With its complete-machining capability the VLC 400 MT also shortens throughput times for medium batches.

Whereas previously each operation took up one working shift before the components could be passed to the next machine, they can now be complete-machined in a single set-up.

This results in greater dimensional, geometrical and positional accuracy as well as in a reduction in work-in-progress.

The primary objective with most machining centers that completely machined components is the delivery of ready-to-install components, not necessarily the degree of their economic viability.

While machining operations are carried out on one work spindle, the other one can either be put to limited use only or cannot be used at all - an uneconomical process, particularly for small or medium batches.

* workpiece pick-up is here of definite advantage - where horizontal machines are loaded by hand, with a particular operator assigned for the task, full automation is often very expensive.

The VLC 400 MT, however, saves the user the outlay for automation equipment.

Instead, the components are loaded directly from the conveyor integral storage section, which in turn is loaded cycle time-concurrent by a workman.

This way, longer unmanned time periods can also be bridged.

Technical and ergonomic benefits The suspended workpiece is a precondition for unhindered chip flow and makes removal of chips from the clamping device easier.

Shorter idle times are a result of shorter tool change travels and the use of linear axis drives.

Sensitive components are located in contamination-free areas.

For instance, the guideways of all major machine assemblies are located above the tooling zone.

All areas in which manual operations or service work have to be carried out are easily accessed.

Short- to medium-term advantages for the user The VLC 400 MT is constructed at right angles to the material flow and therefore ready to be integrated into production lines.

The versatility of the machine ensures that the user's investment is safe if component spectrum or batch sizes should change.

The VLC 400 MT is put together from components that stem from the EMAG Group's modular machine design.

Two recently installed multi-axis mill-turn centres at a precision engineering company are being used to machine complex, high-precision parts with fewer set-ups and in less time.

Precision Engineers - Slack and Parr - has recently invested in two Doosan Daewoo MX 2000ST multi-axis mill-turn centres supplied by Mills Manufacturing Technology, UK. The two new machines, installed at the company's Kegworth plant in January 2007, take the total number of Doosan Daewoo machine tools purchased by Slack and Parr to an impressive nineteen. These latest investments have also tripled the number of MX mill-turn centres Slack and Parr has at its disposal.

(The company's first MX machine was delivered in October 2005).

All three of the company's MX mill-turn centres are being used to machine complex, high-precision parts - and are helping the company improve its productivity and maintain its competitive edge.

Slack and Parr managing director Richard Hallsworth said: 'We operate in highly-competitive global markets and sectors'.

'Making strategic investments in the latest and most advanced machine tool technologies (like the MX machines) is crucial, helping us become more efficient and productive.' He explained: 'The MX machines enable us to benefit from 'one-hit' machining - and that means better machine tool utilisation, reduced direct manufacturing time and resources, fewer set ups; less production bottlenecks; quicker throughput...and higher quality too - as risks of errors between individual machine operations is eliminated.' * About Slack and Parr - Slack and Parr was established in 1917 and was first involved in the manufacture of parts for the growing UK motorcycle industry.

Since then the company over 90 years has 're-invented' itself and diversified its business activities considerably.

Today Slack and Parr has three core business and manufacturing areas of concern.

1 - The design, manufacture, assembly, sales/distribution and service of its own high precision gear metering pumps primarily used in the man-made fibre industry.

2 - The manufacture of high-precision components for the aerospace and F1 sectors.

3 - The design and manufacture of precision hydraulic rotary flow dividers used extensively in agricultural, construction, materials handling equipment, etc.

Today the company employs 200 people at its Kegworth facility.

* Core business and the MX 2000ST machines - Slack and Parr's MX machines are being used to manufacture the following.

i) Components for the company's Gear metering Pumps.

ii) high-precision (sub-contract) complex aerospace/F1 components.

* Precision Gear Metering Pumps - Slack and Parr's Precision Gear Metering Pumps have an international reputation for quality and this part of the business accounts for over 70% of the company's turnover.

Slack and Parr gear pumps (e g, Planetary Pumps; Polymer Metering Pumps; Spandex Metering Pumps and Spin Finish Oil Pumps, etc) are mainly used in the man-made fibre industry.

Operating 'around the clock' (24/7) in high temperatures (up to 300 deg C) - the critical success factors for Slack and Parr's gear pump customers are reliability and achieving very accurate and consistent flow rates.

Anything less than guaranteed 100% performance by the pumps will affect the quality of the product (Spandex, Lycra, Aramid, PET, PA6 etc) and create downtime in the manufacturing process.

To safeguard the quality and performance of its pumps and constituent components - and to make its own manufacturing processes and systems more efficient and robust - Slack and Parr has invested in its second (for this part of the business) MX 2000ST machine.

Continued Hallsworth: 'The MX machines are used to machine complex planetary pump plates from tool steels.

These machining operations occur prior to heat treatment and accuracies of +/-0.025mm are required.

In the past (prior to MX machine installation) most of the operations involved in manufacturing the plates were performed on our horizontal and vertical machining centres.

This method required three separate machine setups (machining both faces and then angle drilling) and manufacturing time per plate was about 40 minutes.' He added: 'With the MX machines - the plates are completed in a single setup and we have reduced the time taken to complete each part down to 20 minutes.

When you consider that we are making something in the region of 8,000 - 10,000 plates per year it's clear the productivity gains we are making.' * Precision component manufacture - aerospace and F1 - Slack and Parr provides high-precision subcontract manufacturing services to a range of clients in the aerospace and F1 sectors.

This side of the company's business accounts for approximately 25% of the company's turnover.

A new MX 2000ST machine has been installed specifically to machine these complex, high-precision and high-value parts.

The parts - typically used in jet engines and aircraft landing gear - are made from a variety of materials - aluminium, titanium, exotics, etc.

and are required in small, medium and large volumes depending on customer order schedules.

Said Hallsworth: 'The aerospace sector is highly competitive and to survive (and grow) within it - we need access to the most productive machines on the market.

High-precision parts that can be produced in less time to the highest quality standards mean that we are able to compete anywhere, and with anyone in the world.

That explains why we have made the investment and why we have a dedicated MX machine for this part of our operation.' * About Slack and Parr and Mills Manufacturing Technology - Slack and Parr and Mills Manufacturing Technology have a business relationship that goes back to 1998.

Over the last 9 years Slack and Parr has invested heavily in machine tool technology from Mills - lathes, vertical machining centres, twin-turret/twin spindle turning centres, etc.

Concluded Hallsworth: 'We are always on the look-out for technology that can give us the edge'.

'The price: performance ratio of the MX machines is second to none - and, through our long-established relationship with Mills, we know we can rely on their help, expertise and product support.' * About the MX 2000ST/2500ST machines - MX multi-axis mill-turn machines are available in two sizes.

The MX machines have a working bar capacity of 65/76mm and are equipped with powerful 22/26kW, 5,000 or 3,500 rev/min turning spindles (left and right).

These spindles have built-in motors that provide high torque output and high accuracy turning capability.

The B-axis rotation of the milling spindle (240 deg rotation, 0.001 deg increment) allows the machining of complex angled features.

The Y-axis (+/-80mm stroke) provides the facility of milling and drilling across centre line, such as contour milling of keyways and cross milling of flat surfaces.

The milling spindle uses Sandvik Capto C6 tooling and produces 18.5kW and 10,000 rev/min with coolant through the spindle up to 70 bar pressure.

The MX machines have a large non-lift servo-driven 12-station, driven-tool bottom turret providing 5.5kW and 4000 rev/min.

Fast rotation (0.2s index time) helps customers reduce machine cycle times.

This turret can be used simultaneously with the upper milling spindle to further reduce cycle times.

To increase productivity still further - the MX machines have a 40-position (80 optional) automatic tol changer with tool pre-select that uses Sandvik Capto C6 modular tooling - achieving 1.5s tool-to-tool changeover times.

The machines are equipped with a Fanuc 18i TB control including a comprehensive control option package as standard.

The control is user-friendly with a high level of diagnostics available to the operator, and offers the highest level of reliability that customers have come to expect from the latest Fanuc technology.

Conversational programming, which is very easy to learn, allows a subcontractor to program most of its CNC lathe jobs on the shop floor - even quite complex work.

The combination of very high skill levels, a detailed understanding of aerospace industry requirements and materials, plus the ability to respond quickly, form the backbone of the business of John Harper and Steve Price, two director partners of Paragon Engineering and Logistics. Paragon is a 26 people subcontracting company formed in 2000 in the UK by two ex-Lucas Aerospace senior managers who have enjoyed ever-growing success from a strong customer support policy. And, having gained its spurs from strict attention to detail, the business now devotes its energies to 'Aerospace Alley' a particular area of the Midlands that forms a corridor of aerospace companies that brings Paragon's customer base to within two or three miles of its 6,000 ft2 machine shop in Bushbury, Wolverhampton.

As a result of being close at hand, the two directors almost run a 'doorstep' service and are in and out of customer plants on a daily basis, creating a high profile of no job too small or complicated.

Having installed five Colchester-Harrison Tornado lathes in two to three- axis variants, Paragon is geared to flexibility.

It needs it - no job lasts longer than two days and batches of parts produced on standard tooling rarely exceed 20.

As Harper explained: 'We live and breathe the aerospace industry and it's jump in the car, go see the customer, come back with drawings and respond.' Paragon machines a wide variety of materials from aluminium to tough experimental steels.

Quite often parts are for development, spares or ramp-up and ramp-down volumes.

For some customers, Harper explained: 'We have to trial and develop speeds and feeds on top secret materials to enable the customer to machine it'.

'This is where our high skill base comes into its own and the machines we use have to be rigid and stable.' The company, for its size, has a very flat management structure, Harper and Price are very much 'at the helm' with everyone else in support.

'No foreman or chargehands,' said Harper, 'our people are so skilled that they are pretty well self-motivating.' The company runs a single day shift from 8 am to 8 pm - no one clocks in or out and people arrive and depart to suit their home lives or traffic conditions.

They know what they have to do and being responsible for their working lives gives them a feeling of running their own business.

For us it pays off too because there are no problems and they respond when we need it,' he said.

Each Tornado has its own setter operator and most programming even for the difficult parts, is carried out at the machine.

'The in-built Colchester Lathe developed Manual Guide i conversational programming software is a very practical package,' said Harper, 'The setters find it quick to learn and they almost play tunes on the control - you must remember, most materials are special so we can't afford scrap and as these guys are setting day after day they are very sharp.' The toolpath verification is ideal when producing a single part enabling the copy and paste of sections of programs when needed.

He explained: 'We have no need to look for cycle time - we look for good work - right is the only way and consistency from part to part is paramount especially on development work and we get this from the Tornado machines.' Most turning jobs on the Tornados tend to be within 125mm diameter by 250mm long and the company buys its exotic material by the metre, half metre or even a single billet from designated suppliers.

Very rare is it that the same batch is machined twice and they vary between a whole range of shaft sizes, gear blanks, end caps and housings.

To which Price added: 'With current JSF project work, this means we often get orders for one trial part.' The first two Tornados a T120M and T220M with 54mm and 65mm diameter bar feeds and driven tools were bought as a package in 2002 with additional capacity derived from a previously owned Tornado 110.

In the summer of 2006 new two-axis T2 and T4 lathes were installed, the latter to provide a larger capacity when needed with a 230mm turned diameter by 450mm long.

Bar capacity is 54mm diameter.

The company also has extensive CNC milling and a full grinding process capability covering surface, internal cylindrical and centreless, but for turning has standardised on Colchester-Harrison.

The directors maintained this devotion to Colchester-Harrison for turning as it provides high levels of familiarity between machines, helps with service support and with sales and service operating out of 600 Centre in Shepshed, said Harper: 'This puts them right on our doorstep because we cannot afford a machine to be idle.'