CNC milling and boring machines

CNC mill-turn centre has bigger bar capacity

2007-02-27T23:48:00.003-08:00

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

Latest CNC cuts mill-turn centre cycle times

2007-02-27T23:48:00.001-08:00

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

Centre gives greater flexibility and low WIP

2007-02-27T23:47:00.002-08:00

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.

Multi-axis mill-turn centres lessen set-ups

2007-02-27T23:47:00.001-08:00

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.

CNC lathes' conversational programming wins

2007-02-27T23:44:00.000-08:00

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.'

Ready-to-install shafts completely machined

2007-02-23T21:04:00.001-08:00

Vertical multi-function turning centres self-load shafts and forgings, complete-machine them - including bores and surface finish - and unload them.

The VTC Vertical Turning Center stands shaft machining on its head. Its 4-axis version VTC 250 machines workpieces of up to 180mm diameter and 630mm length (1000mm optional). The larger version VTC 315 machines axle-type components of up to 315mm diameter and 700mm length.

In its DUO version the VTC offers two stations for end machining and turning work.

Common to all the machines is their ability to self-load the shafts and forgings, complete-machine them - including bores and surface finish - and unload them.

The VTC Shaft Turning Center was developed under the same governing principles that led to the success of the turning machines for chucked components.

The cornerstone of the VTC, like that of all other turning and production centers from EMAG, is the sturdy machine base in Mineralit polymer granite.

Its vibration damping properties lead to a better surface finish and a longer tool life than those of conventional materials.

Spindle motor, work spindle, turrets and electrical cabinet are all fluid-cooled.

Its superior power rating, the high spindle speeds and the sturdy turrets that accommodate tools with 40 mm shank, make the VTC 250 a highly efficient turning center for 4-axis machining.

Tailstock and steadies are CNC-controlled.

In addition to the workpiece grippers, the remaining 11 positions of each of the two turrets can be equipped with stationary turning tools or with live tools for drilling and milling.

The VTC 250 turns workpieces of up to 180mm diameter and 630mm length (1000mm optional) and features VDI-40 workholding equipment.

The highest torque rate is 380 Nm, the maximum workpiece weight 20kg.

The machine is designed, primarily, for the manufacture of gear shafts for passenger cars.

The larger VTC 315 machines axle-type components of up to 60kg in weight, 315mm in diameter and 700mm in length and employs VDI 50 workholding equipment.

Its highest torque rate is 800Nm.

The machine is used, primarily, for the machining of HGV gear shafts.

Both centers work with four NC axes.

The VTC is available as a single-spindle machine and in a DUO version.

The latter combines the functions of two 4-axis turning machines and accommodates end working and turning operations in two machining stations.

The processes are integrated into one and the same sequence.

The two turrets carry out the cycle time-concurrent loading and unloading of raw-parts and finish machined components in the simplest way imaginable: 1) The gripper in turret no.

1 picks up the next workpiece from the raw-part storage section.

2) Conveys it to the clamping position, whilst - cycle timeconcurrent - the gripper in turret 2 picks up the finish-machined workpiece from the clamping position.

3) Removes it from the machining area and deposits it on the storage conveyor for finished components.

It has taken many enterprises only a very short time to opt for this new generation of machines, to machine short, medium size and long shaft-type components, using steadies for support.

The VTC machines are also increasingly converted to multifunctional production centers by including, for instance, end machining operations, such as sizing and centring, as a preparation for subsequent 4-axis turning, or as downstream machining operations - each of these steps as a fully automatic sequence on a single machine, of course.

The VTC design offers the following additional advantages: * 4-axis machining reduces cycle times - the cycle time-concurrent loading and unloading of the workpieces.

* Reduces idle times - the compact construction makes for a smaller footprint.

* A reduction in the cost of automation and peripherals (raw-part and finished component storage systems form an integral part of the machine).

* Less manual intervention (tailstock and steadies are CNC-controlled, whilst the operator has easy access to the turrets).

* Shorter setting-up and resetting times - direct-drive machine axes and modern control technology reduce the capital outlay for sensory equipment.

Mill-turn centre has automatic crash protection

2007-02-23T21:03:00.000-08:00

Latest multi-function machine for turning components, in the same set-up, performs prismatic machining operations using an 11kW milling spindle mounted on a swivelling B-axis.

Okuma has launched a new, multi-function machine for turning components with up to 15kW (optionally 22kW) of main spindle power and, in the same set-up, performing prismatic machining operations using an 11kW milling spindle mounted on a swivelling B-axis. Called Multus B300, the slant-bed machine is capable of high accuracy in a normal shop floor environment, as tests have shown thermal deviation to be less than 10 microns over a 24h period despite a variation in ambient temperature of 8 deg C. This performance is a result of the application of Okuma's patented Thermo Friendly Concept to both the machine structure and the spindle, together with the use of 0.1 micron resolution linear scales in the orthogonal axes.

Available in the UK through sole agent, NCMT, the machine has the added benefit of the manufacturer's new OSP-P200 control, which uses an industrially-hardened PC to run both the Okuma operating system and Windows XP.

It is therefore possible to display Excel files listing machining instructions, tooling, offsets and performance results.

Two USB 2.0 ports are provided for program download, data capture and even the attachment of a bar code reader.

A new feature of the control is the most comprehensive collision prediction and avoidance system currently available.

The entire machining area is monitored in real time during an automatic machining cycle or, unusually, in manual mode as well, preventing the axes being wound by hand into a collision situation.

Whereas the focus of competitive simulation and interference-checking software is on the tool, holder, spindle and fixture, in addition to the component, Okuma takes a wider view, mapping also the spindle head, slideways and guarding.

The result is a reduction of up to 40% in the time needed to write programs involving the simultaneous interpolation of multiple axes.

Deriving from Okuma's MacTurn range of B-axis lathes, which include a conventional live tool carrier, the competitively-priced, single-turret Multus is nominally an 8in (or 10in) chuck machine that turns components up to 630mm diameter by 900mm long.

Weighing around 10 tonnes, it is capable of high precision machining - typically under 3 microns total tolerance on roundness of a component.

Nevertheless, it can remove S45C steel quickly - for example taking a 5mm depth of cut at 0.5mm/rev feed rate during OD turning, or milling 360cm3/min when roughing.

Such big, complex machines can often be cumbersome to use, but not so with the Multus.

Its spindle centreline is a little over a metre from the floor and 500mm in from the guarding, there is a lightweight door for ease of use, a swivelling operator's panel for the OSP control, and a coolant tank that detaches from the front, rather than having to slide it out lengthways.

Access to the magazine for exchange of HSK A-63 (or Capto C6) tools is similarly quick and easy, standard capacity being 20 stations, with 40 or 60 oprtional.

Roller bearing linear guideways allow weight-bearing capacity and precision to be combined with 40 m/min rapid traverse in X and Z, 26 m/min in the +/- 80 mm Y-axis and 20m/min for the W-axis motion of the optional, opposed spindle.

The latter is of equivalent capacity to the main spindle, offering up to 5,000 rev/min in two speed ranges.

The milling spindle, which swivels through 225 degrees in 0.001 degree increments, is powered by Okuma's patented Prex reluctance motor which drives both head rotation and the live tool at up to 10,000 rev/min.

Spindle design quality boosts turning accuracy

2007-02-23T21:02:00.000-08:00

Performing machining trials over 30 components from 42mm diameter brass bar, the latest turning centre maintained a size tolerance within 3.5 microns, qualifying the quality of the spindle design.

Performing machining trials over 30 components from 42mm diameter brass bar, the latest Hyundai Super Kia SKT 15 turning centre maintained a size tolerance within 3.5 microns. In further machining trials over a series of 30 mm diameter aluminium parts, a roundness of 0.5 microns was achieved, qualifying the quality of the spindle design, and machine build with the repeatability available from the closed-loop measuring system employed. The new Super Kia machines designated under the 15/21 Series is now available from C Dugard of Hove in Sussex, UK, and can be specified in two-axis bar and chucking formats, with options to upgrade the specification to include subspindle and driven tooling.

Bar capacities are 44mm for the SKT 15 and 66mm diameter for the larger SKT 21.

On the larger machine, swing over cross slide is 350mm and maximum turning length is 410mm.

Hyundai-Kia is, by some significant margin, the largest builder of machine tools in Korea and has developed the SKT to provide higher accuracy and short cycling over a wide range of components.

Constructed on an exceptionally rigid single cast iron bed, it carries a three piece coupling designed turret with hydraulic clamping and a thermally symmetrical headstock with direct drive spindle.

Both the spindle with 11kW or 15kW motor giving 6,000 or 4,000 rev/min respectively and axis drives to the 12 station turret, have been specified for fast acceleration to minimise non-cutting times with the spindle able to accelerate to 6,000 rev/min in 2.2s and the rapid traverse from zero to 36m/min in 0.1s.

Both the SKT 15 and SKT 21 have a wide range of options such as driven tools for every turret station and a C-axis.

Tools are powered by a 3.7kW, 4,000 rev/min motor giving a drilling and end milling capacity of 20mm and M 16 for tapping.

When the subspindle is specified for 'one-hit' production cycles the chuck size is 135mm and is powered by a 3.7kW, 6,000 rev/min motor.

Indexing at 5 increments can also be added to cater for more complex work.

Rapid traverse of the subspindle is 30m/min for quick automatic part transfer from the main spindle.

A parts-catcher is optional to service both the main spindle or subspindle.

A one-touch tailstock is available having a 9s positioning time at 3 m/min rapid traverse rate.

Clamping and unclamping is automatic and the retraction rate is doubled to 6m/min to reduce lost cycle time.

Quick-change chuck jaws that can be exchanged within one minute are optional and a Q-Setter is standard to enable tool offsets to be automatically captured.

Demand grows for advanced mill-turn centres

2007-02-23T21:01:00.000-08:00

Turning centres machines are now becoming a machining centre as well as a lathe and more users are purchasing this type of machine to make complex parts in one set-up.

Steeped in a tradition of high specification machine tool sales and distribution, Macro CNC of Brierley Hill in the West Midlands, UK, has sold the renowned Japanese Miyano turning centres for over 25 years. In this time, the manufacturing industry has changed drastically and it has required machine tool development to do likewise. Macro CNC has also changed.

* Changes at Macro CNC - to meet the evolving market needs, Macro CNC has also undergone change.

Acquired by Miyano in 2001, the now Macro CNC general manager John Stretton commented: 'One of the aims for 2006 was to enforce the Miyano name upon the UK marketplace and this will continue into 2007.

However, not only has the company changed but so has the marketplace.' The fast pace of change has also noted Miyano forming an equity and business alliance with Citizen Machinery Co, a division of Citizen Watch Co in recent weeks.

This alliance sees Citizen acquiring a 29.9% stake in Miyano Machinery.

However, concentrating on the product range Stretton continued: 'More customers are making extremely intricate components.

However, customers also want more flexibility to coincide with their complexity.

The goal is all about making complex parts, which is changing the development of the turning centre.

Our machines are now becoming a machining centre as well as a lathe.

More customers are now purchasing the Miyano ABX range of machines.

This is because companies want to make complex parts in one set-up.' * Evolving market needs - with the market demands requiring the ability to produce a wide variety of complex parts with the minimum of changeover times, the Miyano ABX range is increasingly in demand.

'The goal of our customers is to leave these machines set-up.

Manufacturers now want to leave all tools set, so the machine setter is only changing the bar size, putting in the program and hitting the start button.

This philosophy drastically reduces set-up and machine downtimes, increases productivity and allows the part to be produced in one operation.

The customer now wants to make lower batch sizes and then change over to another part very quickly,' continued Stretton.

Customers are looking for flexibility as well as savings on the cycle times and meeting all these demands has seen the machines evolve.

Unmanned running is increasingly in demand and to meet this, tool monitoring is now standard, drill and part off breakages are also monitored to allow the machines to run unmanned.

The company recently supplied a machine with 22 driven tools that spends 50% of its time conducting prismatic machining operations.

'For us as a company, this has changed the business drastically in the course of 2006; the size of the projects has undoubtedly increased.

This change of project size has increased our applications work.

The ABX range of machines from 51mm to 64mm diameter is allowing us to do this - we can now mount 72 tools with 36 of them being driven.' Stretton continued: 'With this complexity we now spend more time with customers, so our support and applications philosophies have changed, we now work more closely with tooling and chuck suppliers and are often working with their OEM specialists.' However, a large slice of the company's success stems from the exceptionally popular Miyano BNJ series of machines.

The BNJ is still the biggest seller with almost 40% of all Miyano UK sales.

'It is a very good value machine that will fit with customers making difficult components below 42mm diameter, yet wanting more power than what is available with a sliding head machines.' Our new 8-axis two turret BNE series of machine and the BND-51SY have both undergone recent developments to meet the evolving needs of the end user.

'As a market leader and an innovator Miyano will be further developing current models as well as launching new products throughout 2007.

Our customers are very pleased with the current range of Miyano options available and with further product launches expected, we are optimistic about our potential for 2007,' concluded Stretton.

CNC turning centres offer power, precision

2007-02-23T20:58:00.000-08:00

CNC turning centres with a swing over bed of up to 720mm and turning length of 1000mm between centres have a drive power up to 46kW and a speed range up to 4,000 rev/min.

Leader CNC of Nuneaton, UK, is proud to announce that it has been selected as the UK Distributor for German manufacturer Monforts, whose range of high specification CNC lathes complements the DMC turning centres and Toshiba and Kitamura machining centres already distributed by Leader CNC. Leader CNC sales director Mike Serzeniewski commented: 'This new agency now puts Leader CNC in an ideal position to offer the marketplace a complete range of machining and turning centres'. 'As expected of a German manufacturer, the Monforts range has an exemplary build quality with productivity and capabilities to compete with just about any turning centre on the market'.

'This range will be supported by our exceptional sales and service ability that has been proven with Leader CNC serving as Main European Dealer for Toshiba Machine and our award for 'Commitment, Innovation and Excellence' from Kitamura Machinery.' * The Monforts range - with over 100 years experience in design, manufacture and assembly of high quality machine tools, the Monforts range will no doubt achieve considerable success of in the UK.

Now available from Leader CNC is the Monforts RNC, DNC, MNC and the KNC range of turning centres.

The RNC line is the main product line available from Leader CNC and it has the SingleTurn, DuoTurn and MultiTurn options.

The RNC 400, RNC 500, RNC 600 and RNC 700 are available with 420, 600, 640 and 720mm swing over bed diameters respectively and a turning length of 600mm (RMC 400) and 1000mm.

Available with Siemens or Fanuc controls the RNC range has a drive power up to 46kW and a speed range up to 4,000rpm dependant upon the option selected.

All MultiTurn machines come with 12 driven tools and a drive power of 12.6kW and 13.6kW dependent upon control selection.

The RNC 400 and RNC 500 DuoTurn series are available with an A6 spindle nose, 64mm spindle bore 52mm bar capacity in the draw tube and a maximum drive power of 22/25kW.

For complete machining of intricate components the DNC 500 DuoTurn twin spindle turning centre will be available with a Z1/Z2 and X1/X2 traverse of 600/600mm and 260/260mm respectively plus an 85mm bar capacity on both spindles.

With two turrets and two spindles this machine is a successful integration of two high performance machines in a single machine concept that enables turning, drilling and milling for complete machining of complex parts.

For machining of larger components up to 90 and 85mm (125mm option available), the MNC 500 and MNC 1000 range of SingleTurn and MultiTurn turning centres are heavy duty machine tools with 12-fold turrets and driven tools delivers a true sense of complete machining.

The driven tools permit the machining of eccentric bores, threads and milled faces.

The MNC can be developed to suit the exacting requirements of the end user with a tailstock or subspindle, steady rest or lower slide, Fanuc or Siemens control and a Y-axis as just a few of the options on offer.

For machining even larger parts up to 1500mm length, the UniCen turning centre from Monforts is available in two variations - the UniCen 500 and UniCen 1000.

The UniCen is a turning and milling centre with up to five interpolating axes including an integrated B-axis permits the machining of free form faces.

This high productivity machine incorporates an NC controlled chain magazine that has 34 tool positions with the option of 60 or 90 tools, which are available in HSK63 or Capto C6 fittings.

As a measure of quality, all Monforts CNC machines incorporate a maintenance and wear free longitudinal guiding system.

This hydrostatic main guide is free of any frictional contact independent of the rate of traverse.

This hydrostatic slideway comes complete with a 10 year guarantee.

Beside the high specification CNC range of turning centres Leader CNC will also be providing the Monforts KNC 500S, KNC 600, KNC 800 and 800S and the KNC 1000 range of conventional turning centres.

With 580, 630, 830 and 1100 swing diameter over bed, this series of turning centre utilises the MTC K series control system with a control philosophy that is suited to the practical experience of the operator.

Combining milling and turning keeps costs down

2007-02-14T21:58:00.001-08:00

The installation of a multi-tasking machine tool at a scientific instrument maker has brought 'one hit' machining capability that extends to producing milled components from bar.

Combining milling and turning keeps costs down The installation of a Mazak Integrex 200 IIIS multi-tasking machine tool at its Tunbridge Wells, Kent factory has provided scientific instrument maker Bellingham and Stanley with a 'one hit' machining capability that extends to producing milled components from bar. 'The performance of the Integrex since its installation in March 2005 has confirmed that this is the way forward,' says Mike Banks, production director. 'Precision machined components, including milled components previously allocated to other machines, are produced from bar in a single set-up, with the Integrex capable of running unmanned in a lights-out environment.

This is streamlining the 'design to manufacture' process, while the savings resulting from rationalising our materials requirement is another contribution to keeping our costs down.' Bellingham and Stanley is a world-leading manufacturer of refractometers and polarimeters.

However, while new designs continue to emerge for export to all parts of the world, this long-established company faces a serious challenge from low labour cost economies.

This means that maintaining low overheads is crucial, and with this in mind Banks has introduced far-reaching changes to the way in which the ISO 9001:2000 accredited company makes its world-class products.

'While the traditional 'big batch' approach ensured the minimum of machine set-ups and changeovers, it all too often resulted in parts 'a' and 'b' arriving in the assembly area while part 'c', the item needed to join them together, was nowhere to be found,' he says.

'It was still in the materials store where rack upon rack of expensive raw material - stainless steels, aluminium, brass and plastics - was awaiting its turn to be machined.

This was matched at the other end of the production process by an equivalent inventory of high value finished components awaiting final assembly.

In effect, this was 'dead' money that could be put to better use.' The imbalance between production and delivery to the customer, and its impact on cash flow, prompted a more flexible response to market demand.

This entailed moving away from 'pushing' work through in large batches and the introduction of a 'pull' system targeted at providing customers with on-time delivery of cost-competitive products assembled on a kit-of-parts basis.' 'It is not possible to change everything in one go,' says Banks, ' But we began by upgrading our CNC machining capability, initially with a small turning centre equipped with sub-spindle, C axis, tool probing and driven tooling.

We equipped our VMC machines, where appropriate, with quick changeover vices, workpiece and tool probing, and pallet changing systems.

We updated our CAD/CAM capability, which is now fully interactive, with DNC downloading of programs on demand from the operator.

More recently, we introduced lean manufacturing techniques to ensure that we machine only what we need, assemble only what has been ordered and deliver a completed instrument as quickly as we can.' The new Mazak CNC machine delivers a fully machined workpiece in one 'hit', which cuts lead times and boosts productivity.

'Of course, it is a major investment for a business employing 50 people,' says Banks, 'But without this level of technology we will be unable to maintain our market-leading position.' The main feature of the bar-fed Integrex 200 IIIS is its combination of 22kW, 5000 rev/min main spindle, 18.5kW, 5000 rev/min second spindle, and upper turret.

This caters for turning, milling, contouring with the C axis, off-centre machining with the Y axis, and milling of angled surfaces with the B axis.

The 15kW, 12,000 rev/min rotary tool spindle moves through 225 deg (B axis) in positioning increments of 0.0001 deg, while the 200mm chucks have indexing increments (C axis) of 0.0001 deg (main spindle) and 0.001 deg (second spindle).

Maximum machining diameter is 660mm and maximum machining length is 1016mm.

'Linking this high specification machine with an 80 tool carousel, quick change collet chuck, and standardised tooling and materials means we can change from job to job in minutes rather than hours,' says Banks.

'This capability is reducing costs in manufacture and providing a far more flexible platform for producing the many precision engineered components used in our instruments.'

Linear motor turning centres suit high production

2007-02-14T21:57:00.003-08:00

Exceptional performance and flexibility have already earned a production vertical turning centre with linear motor powered axis drives a high reputation in the automotive industry.

Exceptional performance and flexibility have already earned the CTV linear Series a high reputation in the automotive industry and similar high productivity sectors. With specific tooling these high-speed vertical turning machines from DMG can also perform auxiliary operations such as milling, drilling and tapping. This versatility has already enabled manufacturers to reduce unit cost significantly making them much more competitive.

With the addition of the new CTV400 linear to the range DMG has opened up this potential to larger diameters.

With a chuck capacity of up to 400mm this top-of-the-range machine has dual-track loading and unloading that can reduce handling time by up to 40%.

The high performance of the machine is complemented by a wear-free linear drive on the 1,620 X-axis that accelerates at 1G for rapid traverses up to 100m/min.

In common with its forerunners, the new CTV400 has an integrated spindle drive whose advantages are significantly greater output, high machining forces and no power loss when the spindle is idle.

Maximum torque is 730Nm and swing diameter, 500mm.

High precision and resolution are assured by the machine's direct measuring systems that also dispense with the need for time-consuming reference positioning.

The fast indexing servo turret - 0.21s for 30 and with 11.3kW on driven tools - greatly reduces idle times.

This is especially true for eccentric drilling and milling operations for which the turret can be equipped with optional Y-axis featuring a +/-100mm stroke.

To ensure good accessibility and maximum security during three-shift operation, the machine base is divided in two.

The compact and rigid base is of cast-meehanite and supported by a cast mineral foundation.

Unusual in a machine of this class, the design provides superior damping capability and a very high machine weight of 13,000kg.

This stability, in combination with the vertical spindle arrangement that supports optimum swarf clearance, creates the ideal conditions for dry and hard machining.

The inclusion of an optional multi-function T-slot plate in the work area greatly enhances the capability of this new heavyweight.

It allows additional tools to be installed in fixed or driven configuration for milling, grinding and boring as well as multi-spindle drill heads or linear tool mounts.

The modular design of this machine allows it to be easily adapted for specific customer needs.

A range of automation options is available to achieve the desired performance.

The machine is controlled by the Windows-based Siemens 840D controller that is of course compatible with the full DMG range of Powertools software support packages including DMG Netservice.

Lockmaker replaces 35 machines with 3 lathes

2007-02-14T21:57:00.001-08:00

At a leading British lock manufacturer, production of plugs, pins, keys and thumb-turns has been transferred from five single-spindle cam automatics to three Traub TNL 12 sliding-head lathes.

At a leading British lock manufacturer, production of plugs, pins, keys and thumb-turns has been transferred from five single-spindle cam automatics to three Traub TNL 12 sliding-head lathes. The ability of the lathes to turn-mill components in one hit has also resulted in the removal of 30 milling, drilling and tapping machines formerly used to perform secondary operations on parts turned on the cam auto's. Space has been freed on the shop floor and five fewer operators are needed on each of two shifts, resulting in a significant labour cost reduction.

A before-and-after comparison of brass plug production gives an indication of the savings being made.

The previous process was to turn a blank from 14mm diameter brass bar on a cam auto; drill six pinholes on a rotary transfer machine; mill a boss on the reverse using a special-purpose machine; drill two holes at the same end on a single-spindle drill; and then tap holes on an adjacent, identical machine.

Between each of the five stages, the components were transferred manually to a degreasing station.

This was necessary as there was always a lot of work-in-progress and parts would frequently be held in bins for three or four days, with the potential to leak cutting oil onto the shop floor.

Economical batch size before setting up all the machines to produce a new component was typically 10,000-off.

On any of the Traub TNL 12 lathes, all of which are equipped with a sub spindle, the plugs are machined completely in one visit to the machine in a 28s cycle.

This is achieved as a result of a generous allocation of tooling, both driven and static, in two turrets and in two gang tool posts for front and reverse end-working respectively.

Batch size is down to around 1,000-off, reducing significantly the money tied up in inventory, bearing in mind that each plug costs UK 28 pence to manufacture.

Another benefit is better component accuracy by eliminating tolerance build-up caused by repeated re-clampings.

Tolerances of +/-0.01mm on diameters and +/-0.02mm for other features are easily held.

The manufacturer advised that Traub sliders were selected for the project as comparative trials on four machines from different suppliers showed the TNL 12 to be capable of cycle times that were on average 10% faster than the next best lathe.

Turning centre machines large, long parts

2007-02-14T21:56:00.002-08:00

A 37kW turning centre with an 11kW milling spindle provides the ideal solution for companies machining long, large diameter components particularly found in the aerospace and oil industries.

Yamazaki Mazak's CyberTech Turn 4500MT turning centre provides the ideal solution for companies machining long, large diameter components particularly found in the aerospace and oil industries. The CT4500MT combines the power of a 37kW, 2400 rev/min spindle, which has a massive 326kgf/m (2360 ft.lb) of torque, with maximum machining diameter and length of 860mm and 3048mm respectively. This powerful turning centre is also equipped, as standard, with an impressive 11kW milling spindle that is equal to many machining centres.

The large upper turret of the CT4500MT 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 0.4 seconds.

Additionally, two boring bars with 80mm diameter shanks and up to 1000mm 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.

The lower turret provides an additional eight positions for OD tools and can be used simultaneously with the upper turret to reduce cycle times through balanced cutting or by combining OD and ID operations.

Furthermore, integral to the CT4500MT is the servo-driven tailstock, which simplifies setup and thrust settings.

The position of the tailstock is recognised by the Mazatrol 640MT Pro CNC, and both its position and thrust settings are controlled by M-code functions.

Confirming the CT4500MT's suitability for the offshore industry is 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.

Yamazaki Mazak has also developed advanced threading software that includes canned cycles for the machining of metal seal threads and re-threading functions.

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.

CNC turning centres offer power, precision

2007-02-14T21:56:00.001-08:00

Turn/mill/drill lathe offers cost benefits

2007-02-08T21:19:00.003-08:00

With C axis and 12 driven tools, a three-axis slant bed CNC lathe offers users a level of single set-up turn/mill/drill capability that is unparalleled on a cost-to-performance basis.

With C axis and 12 driven tools, the Taiwan Takisawa EX-308 three-axis slant bed CNC lathe now available from Ward CNC of Sheffield offers users a level of single set-up turn/mill/drill capability that is unparalleled on a cost-to-performance basis. Coupled with the use of a heavy-duty cast iron bed that promotes powerful and stable operation, the machine's four-track super rigid precision linear guideways and high-speed servo turret combine with the Fanuc 21iT CNC to provide users with an exceptional 'Japanese quality at Taiwanese prices' package. With a swing over the bed of 450mm, the EX-308 has a between centres distance of 645mm and a maximum turning diameter and length of 260mm and 530mm, respectively.

The 52mm bar capacity machine has rapids of 20/24m/min and a spindle speed of 30-4,000 rev/min from the 11/18.5kW motor.

Driven tools speeds are 40-4,000 rev/min.

Auto tool setting arm and parts catcher are standard, and the use of the optional auto toolsetter, bar feed and robot interface systems can significantly enhance the machine's capability for the unmanned production of complex parts.

Achieving productive 'one-hit' machining

2007-02-08T21:19:00.001-08:00

Twin-spindle twin-turret CNC lathe fitted with a robot part-loading system has transformed a general subcontractor into a world-leading brand in the mountain bike aftermarket.

Hope Technology chooses Nakamura for productive one-hit machining A combination of enthusiasm and innovation has helped Hope Technology transform itself from a general subcontractor into a world-leading brand in the mountain bike aftermarket. As part of its long-term manufacturing focus Hope has recently invested in a Nakamura-Tome WT-150 twin-spindle twin-turret lathe supplied by Turning Technologies. The new machine, which is fitted with a robot part-loading system, is part of Hope's drive for continuous improvement of its processes - with the emphasis on high-quality, repeatable and productive one-hit machining.

Simon Sharp and Ian Weatherill, the co-founders of Hope, started their careers as apprentice toolmakers at Rolls-Royce and went on to set up their own subcontracting company.

They had always been interested in motorcycle trials riding and mountain bikes, so after a few years in business it is not surprising that they turned to making what interested them.

'We could see that the technology on a trials bike was eventually going to be applied on a mountain bike and saw an opportunity,' says Sharp.

'We made a front hub first, went to a few mountain bike races and it took off from there.' Hope now makes and markets a range of hydraulic disk brake systems for mountain bikes, as well as stand-alone hubs and other ancillary equipment.

'A lot of the mass-produced products on the market are cast, but we believe that machined parts are stronger, better balanced and more attractive - all our hubs are machined from billet,' says Sharp.

As well as quality, Hope is also focused on process improvement by reducing production times, handling, and the number of operations.

'That is why we bought the Nakamura WT-150,' says Sharp.

'We are making 30,000 to 40,000 hubs a year and we will now be able to do them in one go rather than two operations as we were doing it before.

This is our first twin-spindle twin-turret machine, but we needed both turrets because there is a lot of machining on both ends of the part.

With twin turrets we can balance the operations to get the best cycle time.' He explains that as well as turning, drilling, tapping and de-burring, each hub calls for a significant amount of milling, making the Y-axis a necessity.

'We are literally starting with a billet and ending up with a finished part that can go straight into anodising.

It has cut out a lot of dead time,' he says.

It takes about 7-8 minutes to produce a hub so the robot is standing idle quite a lot of the time, but it is still cost-effective because there is no downtime and no need for an operator to keep loading parts.

But to automate effectively it is vital to have the right machine tool to build the system around, and Simon says it was Nakamura's good reputation for quality and process stability that led him to decide on the WT-150.

'It is a machine designed for production, and what we really like about it is that it is very accurate.

We do not have to adjust the offsets very often and the repeatability is very good.

That is important to us.

We talked about putting probing on the machine, but realised that we did not really need it.

If you are going to adopt unmanned running you need to be sure that the process is very stable.' Before deciding on the WT-150 he looked at a variety of other ways of doing the job, including a vertical lathe loaded with billets.

The problem there, he says, was that you have to have turnover stations and it can get quite complicated when you try to locate the second side.

Sharp also looked at a gantry loading type of machine, but that was quite an expensive option and not as flexible as using robot loading on the Nakamura.

'With the WT-150 you do not have to worry about locating the part as you are loading a plain billet and the machine knows the orientation it is in when you transfer it between spindles,' he says.

For the hubs the robot is loading cut billets.

65mm diameter and, as Sharp points out, if you wanted a barfeed machine to cope with this diameter it would have to be a big machine.

'A bar-fed twin-turret machine to do this job would have to be a pretty big piece of kit and a lot more expensive as well.

And once you start having to turn bar that size all the spindle speeds start to get much slower.

Mill/turn centre makes most use of 3D-CAD

2007-02-08T21:18:00.001-08:00

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.

Sliding head automatics are misunderstood

2007-02-08T21:17:00.001-08:00

Richard Turner reports that misconceptions about sliding head automatic lathes mean companies are missing out on the productivity and cost benefits of multi-turret fixed head machines.

In the past few years we have seen more and more parts in the smaller size range produced on 25 to 32mm capacity sliding head machines. These machines are designed to produce long slender components - and for that type of part nothing can beat them. But people have run away with the idea that they are designed for all types of small turned parts.

For most parts above 20mm in diameter, and for many smaller parts too, a fixed head, multi-turret machine may be able to make them in half the time with less waste.

The reason for this is that, with one or two exceptions, the fixed head machine manufacturers have neglected this size range and left the field wide open to companies offering sliding head machines.

In the last couple of years Nakamura has moved to redress the balance by introducing fixed head machines specifically designed for the highly productive manufacture of small components.

Nakamura initially introduced the WT-100, a 42mm capacity machine specifically designed for producing parts down to less than 10mm.

It has two turrets, a Y-axis on the top turret, twin spindles for simultaneous machining of first and second operations - and a lot more power than a sliding head machine.

With up to 7kW on the driven tools and 11kW on the spindles we can use modern tooling technology to its utmost potential and really attack cycle times - literally halving them in many cases.

More recently, the company introduced the Super NTY3 twin-spindle machine - with three driven-tool turrets, each with Y-axis machining.

This means that up to 96 tools are immediately available, including 36 driven tools, for simultaneous cutting with three tools.

You've not just got two turrets that are truly flexible to either spindle, you've now got a third turret that can work between the spindles as well.

So with three Y-axis turrets you have a unique and absolutely flexible capability.

The cycle time improvements are not the only reason for choosing fixed head machines.

The beauty of the sliding head machine is that the part is supported by a bush, so the tool is cutting right up against the bush, which means it is very rigid when you are producing shaft-like parts.

But once you have fed the material through the bush you can't go back to it - so you generally have to produce the finished diameter in one pass.

That means that you have to compromise on the cutting conditions.

If you are going from 32mm down to 5mm, yes you can do it, but you may have to use lower feed rates and this will lead to problems with swarf.

This is why the fixed head machine is so much better on the majority of turned parts.

Another cost advantage of the fixed head machine is that there is no need to use high-quality bar as raw material because it is being held in a conventional chuck rather than passing through a precision bush.

There is also a lot less waste.

On a fixed head machine the waste at the end of a 3m bar is literally the length of the component and the grip length of the collet, whereas on a sliding head machine you can lose up to half a metre of material per three metre bar.

That's maybe not such an issue at the smaller sizes, but it can be on larger diameters, and when you are working in expensive materials such as brass.

Given these lower operating costs, combined with the lower capital cost of the Nakamura machines, 'UK turning' can add substantially to its 'bottom line'.

* About the author - Richard Turner is with Turning Technologies UK - distributor for Nakamura-Tome high precision turning centres and CNC lathes.

Vertical turning lathes can be customised

2007-02-08T21:16:00.000-08:00

Aero engine rework companies ar are buying standard vertical turning lathes - built from modules - and tailored to suit the requirements of this specialised market.

Webster and Bennett International - based in Warwick, UK - is building standard and customised CNC vertical turning lathes from 1000mm to 2500mm diameter capacity. Using standard modules, the company can offer very simple or very advanced, 'tailor-made' machines at attractive proces. The company also builds a universal vertical turning, machining and grinding centre - a very cost effective product.

In the very busy aero engine rework sector, companies are already buying Webster and Bennett standard machines tailored to suit the requirements of this market.

Second rams for grinding - built into the CNC swivelling saddles, are one new benefit.

Another innovation allows eliptical turning.

* About Webster and bennet International - Webster and Bennet is a daughter company of the Ogepar group, which has manufacturing and trading companies throughout Europe and Africa.

The group includes Pegard Productics, Balliu, ABC Diesels - both based in Belgium - and KBB in Dresden, Germany.

pegard productics builds very large, precision horizontal boring and milling centres.

Balliu builds laser machine tools while ABC Diesels build marine diesels, locomotive power units and power generators.

KBB manufactures turbochargers.

Webster and Bennett has achieved success - 13 orders - in the German market and orders from UK, Belgium, The Netherlands, Canada and Egypt.

Turning centre added to subcontract facility

2007-01-30T21:38:00.001-08:00

Although predominantly a user of CNC sliding head automatics, a machine shop recently purchased a Miyano BNJ-42SY turning centre to increase flexibility and respond to customer needs.

Meeting the needs of an increasingly changing marketplace requires considerable manufacturing flexibility - something Target Precision of Harlow knows only too well. Predominantly a sliding head lathe subcontractor, the company recently purchased a Miyano BNJ-42SY turning centre from Macro CNC to increase flexibility and respond to customer needs. The BTMA member has 11 sliding head turning centres, with a maximum capacity of 32mm diameter.

The addition of the Miyano BNJ-42SY turning centre now allows the company to machine complete parts in one-hit up to 42mm diameter.

Specialising in the high end aerospace, automotive, defence, electronic, medical and telecommunication industries, the ISO 9001 registered company placed its order for the machine at the EMO exhibition in Hanover, Germany in September.

Since the introduction of the new machine, Target Precision has expanded its capability and already grown its customer base.

Manufacturing manager at Target Precision, Dean Hayward comments: 'We had the machine delivered within weeks of the EMO exhibition and it has already proven a valuable asset to the company.

The majority of our turning centres are for small parts manufacture with the exception of a Citizen M32 sliding head machine that will manufacture up to 32mm diameter.

Since the arrival of the Miyano, we have freed up capacity on the 32mm machine and we have reduced our lead times for parts in the 30 to 42mm diameter range by two weeks.' For the process of machine selection, Target Precision specified a powerful and rigid machine that could be set-up quickly to produce short turnaround parts with small batch sizes.

The twin turret Miyano BNJ-42SY certainly met the criteria as Hayward continues: 'We looked at other machines in the market and did time trials with numerous parts and the Miyano came out top by a long way.

An example of a trialled part was a component that required letter rolling.

Competitor machines did not have the rigidity to successfully machine the part whilst the Miyano BNJ-42SY with Y-axis capability, not only completed the part, but reduced cycle times.

With batch runs from 100 to 700 parts plus - this was a considerable saving.' The successful production of this component demonstrated the power and rigidity of the 7-axis BNJ-42SY - both criteria of significant importance to Target Precision as it machines a considerable amount of stainless steel and other difficult to machine materials.

'Target Precision operates its facility lights out and the Miyano BNJ-42SY will fit this working ethos perfectly.

We are currently machining batches from 250 to 1000 with some runs of up to 5000 parts.

The Miyano will enable us to set the machine at the end of the day and leave it run throughout the night - whilst giving us the confidence and peace of mind that it will run at a highly productive rate,' says Hayward.

'As a company, Target is committed to investing in facilities that consistently enable us to deliver the highest levels of quality and service to our customers.

This most recent acquisition is further testament to our high level of customer support and service,' concludes Hayward.

Vertical turning lathes can be customised

2007-01-30T21:35:00.000-08:00

Lathe load/unload system integrates with handling

2007-01-25T03:57:00.001-08:00

Multi-function CNC lathe builder has developed an integrated loading and unloading system within the existing machine footprint and it integrates with user specified material handling systems.

The European Machine Tool exhibition EMO 2005 was the launch pad for Colchester Lathe's expansion of its 'Lights-out' productivity package introducing new levels of automation involving multi-axis machining technology. At the exhibition, the six-axis Tornado T8MSY driven tool lathe with a Y-axis cross feed to the turret and the fully integrated seven-axis T6MS turning cell with a programmable APL5000 automatic loading system were demonstrated to wide acclaim of the company's international distributors and customers at the show. Over the last 12 months Colchester Lathe has pushed ahead its design and development programme and simultaneously re-organised the production of Tornado lathes at Heckmondwike in West Yorkshire to enable assembly to build the new machines using a cell-based strategy.

This was a major change to the previous flow line principle for the more simple two-axis Tornado machines that took market leading shares for the value for money turning solutions they provided.

The whole machine shop has been re-organised with its two flexible manufacturing systems running around the clock alongside large mill/turn centres and slideway grinding equipment.

Sheetmetal assembly for guarding, previously produced at a Colchester Lathe facility in Halifax is now fully integrated onto the shopfloor at Heckmondwike working double shifts with support of Electrox CNC laser profiling, press brakes and a new automated powder coating and cleaning plant.

In addition, individual welding cells now fabricate the bases for the Tornado lathe with a special area dedicated to ensure the base fill of the lathe structure with an engineered polymer concrete is correctly administered.

This is an important part of the company's patented 'Duo-Stable' construction that improves machine stability by some 300%.

Now with the two-axis, three-axis with driven tools, six-axis with driven tools, sub-spindle and Y-axis and seven-axis machines with integrated loading in the portfolio, the whole concept of design and build has changed while the 'value-for-money' philosophy has been retained as a 'brand' marker to this very competitive sector.

The T6MS APL is a totally novel Colchester development that integrates a loading and unloading system within the confines of the existing machine footprint.

At a stroke, this new development provides users with a 'Lights-out' chucking lathe machine package capable of extended running in unmanned situations with the loading system having the flexibility to integrate with user specified material handling systems such as part stockers, carousel palletising or conveyor systems.

In addition, such has been the detail involved in designing the system that it can be switched-out and parked clear of the working area allowing the machine to operate in a normal manned fashion.

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.

As a result, loading sequences are combined with first and second chucking operations having automatic part transfer between main and subspindle for parts up to 80mm diameter by 100mm long and weighing up to 5kg.

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.

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

The 15kW, 6,000 rev/min main spindle 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.

Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that uses an encapsulated polymer concrete base fill mounted with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.

Vertical boring/turning machine cuts cycle times

2007-01-25T03:56:00.001-08:00

A large-capacity two-axis vertical boring and turning machine - with high table speed - has been acquired by an aircraft engine component supplier to further reduce cycle and lead times.

When Paul Pochciol talks about product quality, service and price as the keys to success, he is not dissimilar to many other heads of manufacturing companies. But when he explains that the continued success of the UK's Manthorpe Group is based as much on the organisation's investment in its employees at it is on high-technology machine tools and production equipment, then it is clear that here is a man with a passion for what he does and for the industries and customers he serves. As head of a group of engineering and building products companies that between them supply own-manufactured products, sub-contract machined parts and fabricated structures, Pochciol has for the past 30 years built a highly successful manufacturing group on a basic, but demonstrably potent, principle: always buy the best machines you can afford - and always employ enthusiastic, motivated people.

'The most expensive and fastest machines mean nothing on their own,' he says.

'But if they are operated by people who are truly committed, then the result can be world-beating.

It is not easy finding the right calibre of staff - you need patience and tenacity - and you have to motivate them by showing them that the work they do, the company they work for and the environment they work in is dynamic and world-class.' He says: 'For too many years too many people in the UK have regarded engineering as a low-prestige industry - quite the opposite to its regard in Germany and Japan.

But there is prestige in engineering - high-quality machine tools operated by educated, skilled people do produce high-quality workpieces - and the Manthorpe companies, and our customer base, are testament to that.' His sentiments are clearly visible at each of the three engineering operations headquartered on the 13-acre site in Ripley, Derbyshire, where the watchwords are 'from concept design through manufacture to installation and commissioning': * Purpose Engineering - a specialist in complex and bespoke engineering packages - for example, the manufacture of a laser measuring machine for high-accuracy roundness measurement of spherical components.

* Wagstaff and Appleton - the machine building division for high-speed packing and packaging applications; particularly successful in the tobacco and pharmaceutical sectors.

* Manthorpe Engineering - a specialist in the multi-axis machining of aerospace alloys.

While the impressive bank of injection moulding machines and scheduled investment in robotic systems in the co-located Manthorpe Building Products Division is undoubtedly impressive - and designed to maintain the group mission of cost-competitive manufacture - it is the Manthorpe Engineering facility that reinforces what 'world class' manufacturing is all about.

Described by Pochciol as a: 'Low profile operation in a very high profile industry sector,' and with clients such as BAE Systems, BPB Gypsum and Rolls-Royce, the Manthorpe Engineering shopfloor is adorned with a host of highly expensive, high-technology machine tools that serve this blue chip, predominantly aerospace-focused, customer base.

Work here includes the supply of various casings for the Rolls-Royce RB211 gas turbine (air intake, intermediate and compressor casings) as well as large high-integrity fabrications for Rolls-Royce engine test facilities.

Indeed, the company recently agreed a further five-year contract with Rolls-Royce Power Engineering for the supply of these casings, in addition to 35 other components.

The latest introduction to the portfolio of machines that produce such high-calibre components is a large-capacity Czech Toshulin SKA 12 two-axis vertical boring and turning machine, supplied by Ward CNC.

The Toshulin's specification typifies an 'outside of the box' purchasing strategy based around installing machines with functionality to further reduce cycle and lead times while at the same time maintaining a clean and pleasant working environment.

All new machine purchases must: * Be capable of multi-axis machining.

* Have high-speed spindles.

* Utilise high-pressure coolant.

* Be supplied as totally enclosed working units to, as a result, eliminate airborne mist.

With maximum swing and facing diameters of 1500mm each and able to accommodate workpieces of 1500mm diameter with a maximum height of 1580mm and weighing 8,000kg, the new Toshulin features a 30-station automatic toolchanger, a maximum cutting force of 44,000N and a rapid traverse rate of 12,000mm/min.

Importantly, and aligning with Manthorpe's continuous improvement edict, the machine's 40kW main motor provides offers table speeds of two to 630 rev/min (compared with the usual 250 rev/min) and was supplied as a self-contained machining cell with 20 bar coolant (with return pump on the swarf conveyor) and mist filtration.

Other machine features include Siemens 840D CNC and four-jaw 1250mm chuck, as well as linear measuring on both X and Z axes.

'We have a lot of confidence in the Toshulin,' Pochciol confirms.

'The new machine - which was especially specified for us, particularly in terms of the table speed - brings our Toshulin VTL tally to three.

Also, one of our main customers uses these machines, and from this perspective it is important that we produce work to the same high standards.' He adds: 'Over the years we have purchased a host of machines from Ward CNC.

Of course, Ward CNC specialises in the types of machines we need in terms of capacity and reliable performance, but we also find it important to work with suppliers that adhere to the same ground rules as us.

Ward has consistently supplied quality products at the right price and backed up with superlative customer service.' With additional investments on the horizon - including another six-figure spend on a single machine - the Manthorpe Group continues its quest to drive down costs through 'working smarter' achieved via machines with faster operating speeds and the capability for increased single-set up working, for example.

And still, Pochciol's views about employee satisfaction are not overshadowed by such impressive machine investments.

'My employees spend a lot of time at work, so it is my duty to make the environment here as good as possible.

At home, they do not live in a mess, so why should they work in it?' The Manthorpe Group's 'people first' policy is also evidenced by the Engineering's Division's apprenticeship programme - which also reinforces how the company has successfully established its 'manufacturing integrator' role with clients such as Rolls-Royce: each year, four Manthorpe apprentices start their induction with a 12-month spell at the aerospace giant's training school.

Thereafter, back at Ripley, the apprentices invariably 'shadow' more experienced operators.

'By year three, these guys are terrific assets - they're invaluable,' says Pochciol.

'And they are essential to this company's continued success.'

CNC machine tools complete in one set-up

2007-01-21T21:57:00.001-08:00

A range of multi-tasking CNC machine tools are designed to machine complex components in one set-up and will be shown at the UK's forthcoming Southern Manufacturing 2007 show.

Yamazaki Mazak attendance at Southern Manufacturing 2007 will be used to emphasise the all-round capability of the Mazak CNC machine tool range, which encompasses everything from two-axis lathes, manufactured at its state-of-the-art European headquarters in Worcester, through to the world-leading Integrex series of multi-function machine tools. Actually on the stand, under power, will be an Integrex 100 IV ST multi-tasking machine and a VCN 410A vertical machining centre. In addition, members of Mazak's engineering and sales teams will be on-hand to discuss how best Mazak can improve your productivity.

The Mazak Integrex range is central to the company's 'Done in One' manufacturing system, whereby components are machined complete in a single machine set-up wherever possible.

This system allows lead times to be greatly reduced while at the same time reducing dramatically the value of work in progress, the number of machine tools required and the overall manpower levels.

All of which have major impacts on the bottom line, irrespective of company size.

'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 considered as a cost-effective option for many small- to medium-sized companies.

Our range of machines offers a cost-effective solution to the machining of virtually any component,' said Dr Damien Cleugh, European Marketing, Yamazaki Mazak UK.

Mill-turn centres get faster programming

2007-01-21T21:55:00.000-08:00

Latest turning and milling centres can be specified for even faster and easier shop-floor programming - up to 70% reduction in programming time in comparison to DIN.

The GMX 200S Series linear turning and milling centres from DMG are designed to provide the highest performance for 6-sided complete machining for standard workpieces up to 1185mm in length and 400mm diameter as well as for bar up to 102mm diameter. Key features include an X-axis linear drive, a 6-channel machine bed, a 12,000 rev/min milling spindle with a long Y-axis and an interpolating B-axis. Additional features absolute measuring systems and a 36-tool disc magazine.

Now both the GMX 200S and 250S linear machines can be specified for even faster and easier shop-floor programming - up to 70% reduction in programming time in comparison to DIN.

This introduction makes mill-turn programming as easy and reliable as that for a universal lathe.

When teamed with ShopTurn on Siemens 840D solutionline, the GMX 200S is fully equipped for graphic programming, simple cycle selection and uninterrupted programme monitoring on the shop-floor.

It also provides 3D workpiece simulation for all turning and milling operations extending to the B-axis contour.

This development turns the GMX 200S linear into a highly cost-effective machine for serial production as well as a flexible multi-purpose centre for smaller batches and jobbing work with no limit on geometric complexity.

The GMX 250 linear with its TurnPlus system on the Heidenhain Plus iT controller builds on this flexibility by providing dual channel control for the shop-floor.

It allows the milling/turning spindle and the turret to be programmed with simple dialogue via a menu-based interface.

Features include multi-channel slide display during automatic operation and a detailed machining time readout giving main and idle time.

Turning centre raises productivity 30-50%

2007-01-13T21:33:00.001-08:00

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.

CNC mill/turn centre has high power and rigidity

2007-01-13T21:33:00.000-08:00

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.

Seven-axis turning centre has integrated handling

2007-01-12T21:32:00.003-08:00

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.

Mill/turn centre makes most use of 3D-CAD

2007-01-12T21:32:00.001-08:00

Interfacing multi-function machining/management

2007-01-11T21:31:00.000-08:00

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.

Three-turret, twin-spindle centre cuts in 4-axis

2007-01-11T21:30:00.000-08:00

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 turning centre has 11kW milling spindle

2007-01-10T21:37:00.000-08:00

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.

Compact universal centre turns bar or chucked work

2007-01-10T21:36:00.000-08:00

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.

Powerful vertical turning lathes have a Y-axis

2007-01-09T21:36:00.001-08:00

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.

Mill/turn centre to show orbital milling

2007-01-09T21:35:00.000-08:00

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 turning centre introduced

2007-01-08T21:35:00.000-08:00

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.

Cell combines turn/mill cycles, runs unmanned

2007-01-08T21:34:00.000-08:00

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.

Compact vertical turning machine to be shown

2007-01-07T21:34:00.000-08:00

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.

Pick-up spindle VTLs are self-loaders

2007-01-07T21:32:00.000-08:00

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.

5-/6-axis turning centres offer high milling power

2007-01-06T21:17:00.000-08:00

Test machining on a mill/turn centre usingtwo spindles, two turrets and Y-axis, has shown that times can be cut by over 40% and the work of four machines carried out by one machine.

Two spindles, two turrets, Y-axis control, and up to eight axes in one complete multi-axis turning package - it has to be the Mori Seiki ZT, which can be seen on stand 5340 at MACH 2006. Combining operations provides significant savings during manufacture. Components which previously required several turning and milling operations on separate machines can frequently be done in one operation on the ZT.

Not only does this reduce machining and handling times, but it also improves quality by eliminating resetting operations and their associated errors, as well as, making far better use of available space on the shop floor.

Test machining by Mori Seiki has shown that machining times can be cut by over 40% and the work of four machines carried out by one machine and one operator.

The ZT machines offer increased capacity.

The ZT1500YB has 1000mm between spindle large noses, a maximum turning diameter of 190mm, bar work capacity of 65mm and Y-axis travel of 100mm, the largest in its class.

Using the technology available on the machine, multiple operations can be carried out simultaneously, integrating processes and balancing machining times to achieve the optimum cycle time.

The ZT's dual turrets include a quick change type turret for VDI tools, dramatically reducing tool change times.

Fast setting further adds to the flexibility of the machine.

Smaller batch sizes are viable, helping users to offer shorter delivery times to their customers, and at the same time reduce inventory levels.

Castings for the ZT have been designed to maximise the stiffness of the machine structure using high quality Japanese manufactured castings, with carefully designed ribbing for optimum chip removal.

Combined with the high output oil cooled spindle, which is 18.5kW on the ZT1500, the machine can achieve metal removal rates of 162.7mlitre/minute at 6mm depth of cut and precision finishes of 1.07 micron Ry.

* MS Pollard at MACH 2006, NEC, Birmingham, UK, May 15-19, Hall 5, Stand 5340.

* About MSPollard - wholly owned by Mori Seiki Co, MS Pollard services and supports Mori Seiki and Hitachi Seiki machines in the UK.

Mori Seiki is one of the world's leading manufacturers of metal cutting machines.

It has its head office in Nagoya, Japan, and employs 3,300 people.

Cutting tool maker invests in mill/turn centre

2007-01-05T21:16:00.002-08:00

A leading supplier of tungsten carbide tooling has invested in a bar-fed mill/turn centre to machine difficult-to-cut tooling materials.

Stellram, a leading supplier of tungsten carbide tooling with manufacturing locations in Europe and North America, has invested in a Matsuura supplied Stama Mill Turn centre Stellram has developed a reputation for providing the best cutting tool solutions for difficult to machine materials - stainless steel, super-alloys, and titanium. The company focuses on these materials, while still servicing general tooling needs for less demanding materials. Stellram has chosen a very high specification Stama MC726MT-G Mill Turn machining centre from the Stama Mill Turn range, configured with a sub-spindle for six-face machining.

Tooling will be produced with this new mill turn, including Stellram's latest product introductions such as high velocity cutters for airframe components, patented anti-rotation tooling for heavy feed milling, plunge milling tools and high feed facing cutters.

Supplied with a proven and integrated bar-feed system, gripper conveyor, 150 tool extended ATC carousel, a 12K HSK63 main spindle with 70bar through spindle coolant and extended deep hole drilling capability, the Stama MC-726MT is part of the ongoing capital investment strategy through out the ATI Corporation.

Stellram's parent company, Allegheny Technologies, (NYSE: ATI), is one of the largest and most diversified specialty material producers in the world.

Speaking of the investment, Hugh Welch, Stellram's UK manufacturing manager said: 'It is a true reflection of our long term objective to invest in the highest specification equipment in order to produce the latest tooling technology.

CNC turning centres sold before the show started

2007-01-05T21:16:00.001-08:00

Two fixed head CNC turning centres - to be shown at the UK's MACH 2006 exhibition - have already been sold, informs a UK supplier, which said the machines will bedelivered after the show.

Two fixed head CNC turning centres - to be shown at the UK's MACH 2006 exhibition - have already been sold, informs a UK supplier, which said the machines will bedelivered after the show. MACH 2006 is already guaranteed to be a success for Macro CNC. Two of the Miyano fixed head turning centres that will appear on stand 5538 have already been sold.

To be delivered to customers immediately after the exhibition, the largest machine, a Miyano ABX-51TH2 two spindle, 51mm capacity three-turret turning centre with two Y-axes is capable of processing high-end parts efficiently in a single set-up.

This machine will be delivered to Mann Engineering of County Wexford, Ireland.

The second machine, a Miyano BNJ-42SY will be delivered to HS Rowe and Partners.

The 42mm capacity two spindle, two turret compact turning centre with Y-axis will be delivered to the company's Kingswinford facility in the Midlands.

The orders for both machines highlight the market trend that sees subcontract manufacturers requiring rigid fixed head turning centres with exceptional capability and a capacity to manufacture larger workpieces.

Mann Engineering, a subcontractor, designer and manufacturer of bar feed systems and bespoke systems for special manufacturing applications has purchased its second Miyano ABX-51TH2 to improve its productivity and manufacturing capabilities.

The current Miyano ABX-51TH2 at Mann Engineering has enabled the company to complete components in one-hit.

The third turret on the machine has provided the company a productivity improvement of 20%.

With such impressive results, the company was intent upon buying yet another Miyano from its Irish agent Premier Machine Tools.

Whilst HS Rowe, a subcontract precision turned components manufacturer will acquire its Miyano BNJ-42SY machine to compliment its current range of fixed head turning centres.

Following the purchase of a Miyano BNJ-42S in 2005, Steven Tyler 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.' At MACH 2006, HS Rowe will also be discussing with Macro CNC the possibilities of introducing automated machines from the LZ series.

5-axis mill-turn centre monitors collision status

2007-01-04T21:15:00.001-08:00

A 5-axis mill-turn centre for one-hit machining of components up to 710mm in diameter by over 1.5m long features advanced collision avoidance - the CNC monitors the machining area in real time.

Okuma has launched a new mill-turn centre for one-hit machining of components up to 710mm in diameter by over 1.5m long. Called Multus B400, the 5-axis machine features advanced collision avoidance whereby the Okuma OSP-P200 control monitors the entire machining area in real time during an automatic machining cycle or, unusually, in manual mode as well, preventing the axes from being wound by hand into a collision situation. Availability in the UK is through sole agent, NCMT.

Whereas the focus of competitive simulation and interference-checking software is on the tool, holder, spindle and fixture, in addition to the component, Okuma takes a wider view, mapping also the spindle head, slideways and guarding.

The result is a reduction of up to 40% in the time needed to write programs involving the simultaneous interpolation of multiple axes.

In place of a turning tool, the swivelling B-axis spindle accepts HSK-A63 (CAPTO C6) tools, exchanged from a 20-station (optionally 40- or 80-station) magazine, for carrying out heavy prismatic machining operations using 10kW (optionally 14kW) of power.

The milling spindle swivels from -30 to +195 deg in 0.001 deg increments.

Both the tool and the motion of the turret are powered by one Prex reluctance motor (Okuma patent), whose absence of windings on the rotor minimises heat generation and promotes accuracy.

Roller bearing linear guideways allow weight-bearing capacity and precision to be combined with 40m/min rapid traverse in X and Z, 26m/min in the +/-115 mm Y-axis, leading to short idle times.

As befits a machine required to turn large components, the C-axis spindle is powered by either a 30/22kW or 22/15kW motor, switchable in two ranges, the former figures representing 30 min ratings.

The 14.5-tonne, slant-bed machine is capable of high accuracy in a normal shop floor environment, as tests have shown thermal deviation to be less than 10 microns over a 24h period despite a variation in ambient temperature of 8 deg C.

This performance is a result of the application of Okuma's patented Thermo Friendly Concept to both the machine structure and the spindle, together with the use of 0.1 micron resolution linear scales in the orthogonal axes.

Big, complex machines can often be cumbersome to use, but not so with the Multus B400.

Spindle centreline is only 1.2m from the floor and 550mm in from the guarding, there is a lightweight door for ease of use, and a coolant tank that detaches from the front, rather than having to slide it out lengthways.

There is also a convenient, swivelling operator's panel for the Okuma OSP-P200 control, which uses an industrially hardened PC to run both the Okuma operating system and Windows XP.

It is therefore possible to display Excel files listing machining instructions, tooling, offsets and performance results.

Two USB 2.0 ports are provided for program download, data capture and even the attachment of a bar code reader.

Mill/turn centre keeps complex work in-house

2007-01-04T21:15:00.000-08:00

Starting from a twin-spindle, twin-turret multi-axis lathe, an electric actuator company engineered a manufacturing system complete with tooling and programs for six components.

When Rotherham, UK-based Precision Magnetics launched an innovative electric actuator for the aerospace industry it took a bold decision. Even though it had no history of advanced machining it realised that it had to make these complex and sophisticated products in-house. Turning Technologies, the UK distributor for Nakamura-Tome and a member of the Engineering Technologies Group, provided the turnkey solution and support that made this possible.

Historically, Precision Magnetics had specialised in the manufacture of extremely powerful Neodymium Iron Boron (rare earth) magnets.

The materials had originally been developed for small powerful electric motors to be used in automotive components such as pumps and windscreen wipers and were also widely used in computer disk drives.

Until a couple of years ago, this was a significant part of the company's business, but the production route was becoming unsustainable in a global market.

The Neodymium ore from China was shipped to the US for refining into sintered bar that was sent to the UK for processing into magnets that were then sent to the disk drive manufacturers in Singapore.

The solution, a manufacturing joint venture in China, meant that Precision Magnetics had to look at new applications for the magnets.

Andrew Myers, managing director of Precision Magnetics, said that this move came as no surprise and the company was already looking to develop value-added applications that incorporated the magnets into more complex components, particularly for the aerospace sector.

Because these rare earth magnets are so powerful they can be used to make electric motors that, weight for weight, are much more powerful than hydraulic actuators.

This makes them particularly attractive for driving control surfaces such as ailerons, rudders and elevators.

But having sold the concept to its Tier One customers, Precision Magnetics then had to look at how it would be able to manufacture the actuators.

'We made the first ones ourselves by buying in the machined parts from a subcontractor,' said Myers.

'But when you sign long-term contracts, you get the benefit of long-term business, but you have to be able to offer year-on-year 'cost-downs.

To be able to maintain the business we had to take some of the cost out - and the biggest cost element was the bought-in components.

The only solution was to make the parts ourselves.' But these were complicated parts in difficult materials and there was no history of CNC machining within the company.

'We did not have any in-house skills so we had to find a partner who could offer us a complete solution,' said Myers.

'After researching the market and looking at a number of possible routes we decided that we wanted to work with Turning Technologies.' Turning Technologies was able to help because it had the right technology to produce the parts in one setting - which the required levels of accuracy demanded, but, perhaps more importantly, Precision Magnetics needed to be able to put its faith in a company that could take them on from basic toolroom machines to the latest multi-axis, 'one-hit' machining techniques.

Starting from a Nakamura-Tome WT-300 twin-spindle, twin-turret multi-axis lathe, it engineered a production-ready manufacturing system complete with tooling and programs for six components.

'They provided the best technical solution and it was based around a single machine.

That was important for us too.

For this application and with our lack of experience we were much happier having just one machine to concentrate on,' said Myers.

The machining requirements were extremely demanding.

The actuator shafts are manufactured from tough stainless steel and with a hollow internal diameter larger than the through bore, and the sleeves that go round them are even more difficult to make.

These are machined from solid inconel to a wall thickness of 0.5mm, so work-holding and handling are critical.

The slightest clamping problem could result in an expensive scrapped component.

As Richard Turner, managing director of Turning Technologies, explained, 'We had to develop a process using a hydraulic steady mounted on the lower turret, together with quick-release mandrels to suit various diameters of sleeve on the right-hand spindle so that we could finish machine the outside diameter to an extremely tight tolerance.

Because of the small batch sizes, changeover times are very important, so we put quick change chucks on both the spindles too.' With the system installed and in full production Myers said the whole project has been a great success.

'We have shown our customers we are investing in the supply chain and becoming a partner.

Turn/mill centre machines 65mm bar stock

2007-01-03T21:14:00.001-08:00

Latest Hyundai-Kia integrated turning and milling centre has been developed for cost-effective 'single-hit' cycles for components produced from bar stock up to 65mm diameter.

Turn/mill centre machines 65mm bar stock Latest Hyundai-Kia integrated turning and milling centre has been developed for cost-effective 'single-hit' cycles for components produced from bar stock up to 65mm diameter. Fitted with a VDI 40, 12 station all-driven turret having +/-40mm Y-axis feed with 16mm tool shank size and M20 tapping capability, the latest SKT 210 SY Integrated Turn/Mill Center from Hyundai-Kia has been developed for cost-effective single hit cycles for components produced from bar stock up to 65mm diameter. Now part of the ever-growing stable of impressive turn/mill centres from C Dugard of Hove, Sussex, UK, this Y- and C-axis subspindle machine has a maximum turning diameter of 240mm diameter at the 15kW, 4,000 rev/min main spindle that carries an 8in chuck as standard.

The subspindle, fitted with a 5in chuck, is powered by a 3.7kW motor giving 6,000 rev/min and a rapid traverse rate of 36m/min.

In order to support milling and drilling cycles at both the main and subspindle positions, 0.001 deg spindle indexing is standard and a manual Q-Setter tool setting probe is fitted to speed toolchange and machine setting.

Axis strokes are 220mm in X, 550mm in Z, 750mm in ZB and +/-40 mm in Y.

The driven tools are powered by 2.7kW motor and the mach

Mill-turn centre changes 1m long boring bars

2007-01-03T21:14:00.000-08:00

Whether turning or milling the heavy duty machining capability of a mill-turn centre - capable of automatically changing 1m boring bars - provides a powerful platform for high productivity machining.

Yamazaki Mazak's CyberTech Turn 4500M made its UK debut 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' 326.3kgf/m (2360ft.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 setup 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.

Mill-turn centre machines complex parts 'in one'

2007-01-02T01:47:00.000-08:00

The combination of three turrets, twin spindles and eight axes in a mill-turn centre allows complex components - in for medium volume production - to be machined in a single set-up.

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 35.7kgf 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.

Mill-turn centres make full use of 3D-CAD

2007-01-02T01:46:00.000-08:00

Key features among the developments of 'fourth generation', 'one-hit' mill-turn centres is the ability to use 3D-CAD, linear guides in all axes, and 0.0001 deg increments in 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 made 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 degree increments on the B and C axes.

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

The Integrex 300-IV 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 26 m/min in Y, with a maximum C-axis rotation speed of 555 rev/min.

Inverted spindle turning centre can hard turn

2007-01-01T01:45:00.000-08:00

Ideally suited to automotive applications, a 26kW inverted spindle turning centre can be used either as a stand-alone machine or combined into an automated two-machine cell.

Where the requirement is to turn and mill large volumes of components Yamazaki Mazak's IVS range is an ideal choice. Ideally suited to automotive applications, the inverted spindle turning centre can be used either as a stand-alone machine or combined into an automated two-machine cell to complete first and second operations in a seamless fashion. The design of the IVS machine delivers a solid platform that lends it to high-volume metal removal and/or hard turning of material in excess of 50 HRc.

The IVS-300M on display at MACH 2006 features a 26kW, 4000 rev/min spindle that can accelerate from standstill to maximum speed in 3.4s and the maximum machining envelope is 350mm diameter by 180mm long.

Rotary tools are driven by a 5.5kW spindle with a maximum speed of 4500 rev/min.

While the IVS 300 is an extremely stable machine it is also extremely agile, with rapid traverse rates measured at 60m/min in the X-axis and 45m/min in the Z-axis.

Acceleration in both cases is 0.9G.

To maintain the highest levels of accuracy and repeatability the IVS 300 employs a scale feedback system on the X-axis.

This system measures the actual distance moved and maintains accuracy over extended periods of operation.

The Z- (spindle) axis is also used to load/unload and facilitate component handling, which in turn eliminates the requirement for gantry load/unload systems.

This reduces both capital costs and the amount of floorspace required.

Also, reflecting the high-volume environment that the IVS machines are aimed at, the 12-position, drum turret can accept rotary tools in any position, and is of the non-lift design that results in a one position index time of 0.2s.

If it is required to index more than one position, the control automatically selects the shortest path to keep non-cutting time to a minimum.

To aid tool setting the IVS is supplied as standard with Yamazaki Mazak's Tool Eye, which can be used to measure tools, register tool data and adjust tool offsets.

Additionally, it can be used to check for tool wear and damage, helping to maintain the machine's up-time.

Turning centre has NC electric tailstock

2007-01-01T01:44:00.000-08:00

An NC electric tailstock that delivers quick set-up with no manual intervention was fitted to a 30kW/3300 rev/min turning centre at MACH 2006 - of 420mm diameter x 1538mm machining capacity.

The Quick Turn Nexus series of turning centres from Yamazaki Mazak combines those crucial elements required in today's modern manufacturing environment - namely advanced technology, productivity and value for money. In designing the Quick Turn Nexus range Mazak completed a thorough review of the basic machine components and used state-of-the-art design technology to arrive at a range of turning centres ideally suited to meet the production needs of businesses large and small. At MACH 2006 the range was represented by the recently introduced Quick Turn Nexus 350MY.

This single 30kW/3300 rev/min spindle machine has a machining capacity of 420mm diameter by up to 1538mm long.

It also benefits from the inclusion of a NC electric tailstock that delivers quick set-up with no manual intervention.

The tailstock provides accurate support even for components that can only be supported by low-thrust force.

Positioning and thrust force is achieved using servo motors and are programmable.

Each position in the 12 station drum-type turret can be used for rotary tools, which are driven by a 7.5kW/4000 rev/min motor.

The versatility of the QTN350MY is complemented by the addition of a 150mm Y-axis, further expanding the machine's possible application areas.

Power is matched by agility, with the X and Z axes having rapid traverse rates of 30m/min and 25m/min respectively.

The resulting fast, vibration-free acceleration/deceleration is due to the use of high-gain servo-control and high-power AC servo motors.

Control is provided by the Mazatrol Fusion 640T Nexus CNC unit that features the easy-to-use Mazatrol conversational programming format.

As a result programming time and program length are considerably reduced and editing of existing programs is simplified.

Additional benefits of the Mazatrol Fusion control are its ability to accept modification of programs with minimum editing, cutting conditions are determined automatically by the automatic cutting condition function, edited cutting conditions are stored and recalled when the same material is used again.

Vertical turning centre size increased

2006-12-31T01:44:00.000-08:00

High-speed vertical turning machines with linear motor drive that can also perform auxiliary operations such as milling, drilling and tapping now include a 400mm diameter chuck capacity.

Exceptional performance and flexibility have already earned the CTV linear Series a high reputation in the automotive industry and similar high productivity sectors. With specific tooling these high-speed vertical turning machines from DMG can also perform auxiliary operations such as milling, drilling and tapping. This versatility has already enabled manufacturers to reduce unit cost significantly making them much more competitive.

With the addition of the CTV400 linear to the range DMG has opened up this potential to larger diameters.

With a chuck capacity of up to 400mm this top-of-the-range machine has dual-track loading and unloading that can reduce handling time by up to 40%.

The high performance of the machine is complemented by a wear-free linear drive on the 1620mm X-axis that accelerates at 1G for rapid traverses up to 100m/min.

In common with its forerunners, the CTV400 has an integrated spindle drive whose advantages are significantly greater output, high machining forces and no power loss when the spindle is idle.

Maximum torque is 730Nm and swing diameter, 500mm.

High precision and resolution are assured by the machine's direct measuring systems that also dispense with the need for time-consuming reference positioning.

The fast indexing servo turret - 0.21s for 30 deg and with 11.3kW on driven tools - greatly reduces idle times.

This is especially true for eccentric drilling and milling operations for which the turret can be equipped with optional Y-axis featuring a +/-100mm stroke.

To ensure good accessibility and maximum security during three-shift operation, the machine base is divided in two.

The compact and rigid base is of cast-meehanite and supported by a cast mineral foundation.

Unusual in a machine of this class, the design provides superior damping capability and a very high machine weight of 13,000kg.

This stability, in combination with the vertical spindle arrangement that supports optimum swarf clearance, creates the ideal conditions for dry and hard machining.

The inclusion of an optional multi-function T-slot plate in the work area greatly enhances the capability of this heavyweight.

It allows additional tools to be installed in fixed or driven configuration for milling, grinding and boring as well as multi-spindle drill heads or linear tool mounts.

The modular design of this machine allows it to be easily adapted for specific customer needs.

A range of automation options is available to achieve the desired performance.

The machine is controlled by the Windows-based Siemens 840D controller that is of course compatible with the full DMG range of Powertools software support packages including DMG Netservice.

Driven units increase NL CNC lathe productivity

2006-12-31T01:43:00.000-08:00

Driven units for the Mori Seiki NL Series of turning machines allow additional machining processes to be carried out in a single setting, reducing downtime and secondary set-up time.

Kennametal's new driven units for the Mori Seiki NL Series of turning machines allow additional machining processes to be carried out in a single setting, reducing downtime and secondary set up time. The units extend the capability of the machine to perform both milling and drilling operations. Setups can be accomplished accurately and efficiently with these units that are either fitted with either the KM interface or a standard ER collet .

When using the units with the highly accurate KM modular interface milling and drilling tools fitted can be precisely pre set offline, the machine can then be set to automatically adjust for the corrected parameters without requiring a test cut.

The savings made in setup time directly translate into higher productivity.

Individual driven units are designed to work specifically with each model variation of the NL series of turning machines to ensure maximum equipment capability.

The driven units feature high precision, wear resistant gears which ensure smooth operation and long tool life.

High-quality seals and O-rings enhance protection against external contamination.Through-coolant capabilities of up to 100 lb/in2 are available.

One of the key design features is high rigidity, enabling higher spindle speeds and feeds and significantly extended tool life.

Dual-spindle CNC lathe machines in one set-up

2006-12-30T01:42:00.000-08:00

A dual-spindle CNC lathe allows turning of double-ended parts in a single set-up on one machine, and addition of live tooling and full C-axis options to the TL-15 increase versatility further.

Keeping parts flowing through a high-production shop is the key to keeping profits flowing into the bank account. Having to move the same part from machine to machine for different operations can increase set-up times, add to manpower costs and reduce part accuracy. The new TL-15 dual-spindle lathe from Haas Automation allows turning of double-ended parts in a single set-up on one machine.

Built on the shop-proven Haas SL-20 platform, the TL-15 CNC lathe features a 15kW vector-drive main spindle with 210mm chuck, and a 6kW sub-spindle with 135mm chuck.

Both spindles provide speeds to 4,000 rev/min standard, and the main spindle has options for 5,000 and 7,000 rev/min.

Maximum cutting diameter for the TL-15 is 255mm, with a maximum turning length up to 380mm, depending on the type of workholding and tooling used.

The TL-15 comes standard with a 12-pocket tool turret that holds a combination of six VDI 40 tools and six bolt-on tools.

Special twin-bore and twin-turn toolholders are included for sub-spindle work.

The addition of live tooling and full C-axis options to the TL-15 increase versatility further by allowing such secondary operations as drilling, tapping and light milling to be performed both on the face of the part and around the diameter.

With these options, the TL-15's main spindle is capable of fully interpolated, bi-directional synchronous motion for milling flats, hexes and flutes.

The end result is a finished part off the machine with no need for additional set-ups or operations.

Combine the TL-15 with the Haas Servo Bar 300 intelligent bar feeder and the automatic parts catcher option, and full lights-out operation is possible.

The new Haas TL-15 CNC lathe - a high-production turning centre at an affordable price.

MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.

Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.

More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.

Multi-tasking machine tool ordered at MACH 2006

2006-12-30T01:40:00.000-08:00

Deep hole drilling and specialist sub-contract company Mollart has ordered an Integrex e-500 H multi-tasking machine, with 3m capacity, to machine complex parts after gundrilling.

Multi-tasking machine tool ordered at MACH 2006 deep hole drilling and specialist sub-contract company Mollart has ordered an Integrex e-500 H multi-tasking machine, with 3m capacity, to machine complex parts after gundrilling. Yamazaki Mazak's MACH exhibition success continues with the confirmation of a substantial order from deep hole drilling machine manufacturer and specialist sub-contract company Mollart . The order is for an Integrex e-500 H multi-tasking machine, with 3m capacity, which will be used in Mollart's extensive sub-contract facility at Chessington.

Its main role will be to machine extremely complex components in a single operation, after the preliminary gundrilling operations.

These components are part of a recently won contract from one of Mollart's customers in the oil and gas sector.

With some of the components measuring up to 2m in length repositioning for multiple operations is time-consuming and costly.

By using the Integrex e-500 H these costs are eliminated and, more importantly, Mollart will be able to guarantee the positional accuracy and concentricity of the multi cavity bores that are a feature of these particular components.

Guy Mollart, Mollart's managing director, said: 'We won the contract to manufacture these components on the strength of our ability to deliver on time and to the highest quality standards.

The Integrex e-500 H will enable us to maintain that business as we can reduce cycle times and lead times, thanks to the machine's ability to complete all operations in a single hit.' He added: 'However, the most important benefit is the fact that single hit machining enables the positional accuracy of the many features of these components to be maintained.

Kinematically-actuated plates move turrets

2006-12-29T03:57:00.002-08:00

Avilion has drastically reduced mill-turning cycle times with a new type of lathe from Index that supports and moves the turrets using kinematically-actuated plates sliding over the bed.

Luxury tap and shower system manufacturer, Avilion, has drastically reduced mill-turning cycle times with a new type of lathe from Index that supports and moves the turrets using kinematically-actuated plates sliding over the bed, instead of conventional compound slides. It is the first of the German manufacturer's C-Series machines to be installed in the UK and was supplied through sole agent, Geo Kingsbury Machine Tools. Said Steve Pope, Manufacturing Development Engineer at Avilion's Rainham factory, 'The twin-spindle, triple-turret, fixed-head lathe produces parts in a single set-up in half, and sometimes one third, of the time taken on our single-spindle, single-turret machines.

Even comparing like with like, surprisingly it is around 30 per cent quicker than our conventional twin-spindle lathes.' Such fast cutting cycles result in part from the opposed spindle having 150 mm of X-axis movement in addition to 600 mm of longitudinal travel - a configuration normally found only on a sliding-head lathe, according to Mr Pope.

The second spindle's movements can be coupled electronically with the two-axis motion of the lower, double-sided, 24-tool turret, which can simultaneously be working with the upper turret at the main spindle, allowing three tools to be in cut simultaneously.

Each turret has a 70 mm Y-axis for extra versatility when mill-turning highly complex components, easily achieving tolerances down to +/- 0.02 mm on seals, +/- 0.05 mm for other features.

Rapid traverse rates of 25 m/min in X and 50 m/min in Z, and acceleration of 1g, are achieved by not having to move a bulky compound turret slide using conventional ballscrews, leading to short idle times.

The distance between the turret centreline and the point at which it is driven is shorter than for a compound slide, making it several times stiffer and more accurate.

Glass linear scales provide positional feedback.

Continued Mr Pope, 'We will produce 30 to 40 of our most complex brass components on our Index C-Series lathe from 13 mm to 65 mm bar, and billets up to 80 mm in diameter, as we prefer to machine our components from solid rather than rely on castings.

Every part will be machined on the reverse and a cycle will often include 50 per cent milling, drilling and tapping; sometimes a lot more.

'Such is the capability of the machine to slash cycle times, 24 hours a day, and reduce unit manufacturing cost that we have been redesigning our components, where necessary, to maximise the capabilities of the C65 lathe.' Again with high productivity in mind, Avilion has invested in one of the very few Kurt Breuning Profimat bar magazines in the UK to feed the Index lathe.

Changeover to a different bar diameter can be carried out in seconds, or a maximum of 10 minutes if the liner needs to be exchanged.

ERP, CRM, BI, SI, SFA, IT solutions explained

2006-12-29T03:57:00.001-08:00

Businesses both large and small are regularly presented with an array of IT 'solutions' with unfathomable acronyms that promise tempting sales and productivity boosts.

Businesses both large and small are regularly presented with an array of IT 'solutions' with unfathomable acronyms that promise tempting sales and productivity boosts. But what do terms such as enterprise resource planning (ERP), Business Intelligence (BI), Customer Relationship Management (CRM), and Sales Intelligence (SI) actually mean? Where did it all start and what relevance do they have for industrial manufacturing and distribution companies.

Before CRM was even dreamt of, there was something called Enterprise Resource Planning (ERP).

This acronym can be traced back to the 1960s and early methods of inventory control, but was later understood as the business strategy that promised to automate the 'back-office', provide financial reporting and control the supply chain.

It was in the early 1990s, when companies first started to build extensive ERP systems to automate and organise their data; that is also when business intelligence (BI) first emerged.

BI is a general term used to refer to the various ways in which a company analyses data, for example financial, operational or sales information, and the increased availability of company data was perceived as a boon for this process.

The initial problem with BI was, however, that as the new systems collected more and more information, it became impossible to extract what was relevant quickly and efficiently and deliver it to employees who needed it the most, rendering the massive amounts of data virtually useless.

Increasingly sophisticated tools and the advent of data warehousing have gone some way towards bridging this gap between available and useful data, but the process can still be complex and expensive.

Meanwhile, this trend towards harnessing and using key data had spread to the 'front office', and heralded the arrival of customer relationship management (CRM) in the mid-1990s.

In the early years, CRM simply referred to the software used to help businesses manage their customer information, predominantly sales force automation software (SFA) that focused on customer contact management.

It is estimated that the global market for CRM services and solutions is now worth 4.8 billion US Dollars, which gives some indication as to how far the market has developed since those early days.

Now businesses can choose from a wide array of CRM 'solutions' ranging from web-based systems aimed at small companies to sophisticated knowledge management solutions suitable for multi-national enterprises with millions of customers.

So where does CRM and related technologies fit with industrial manufacturing and distribution companies?

Traditionally, industry has been at the forefront of technology, but often in terms of front office software it has been a little slow in adapting to new technology, mainly because the implementation of a new software system has traditionally required a disproportionate amount of time and caused a similarly large amount of disruption.

There are also unique challenges faced by large scale manufacturers and distributors in that the sheer size of the average product range and inventory means there is a huge amount of data to handle and there will inevitably be legacy systems to deal with.

The need to win market share in a climate of increasing consolidation also means that they cannot afford to rush into a software purchase without being certain it is tailored to their needs.

In any industry, the key to making a decision about buying software is to be sure you understand what business problem it is actually a 'solution' for.

This may seem obvious but it's surprising just how few businesses actually take the time to do this and end up buying software that is too expensive, too onerous to fully implement and that the company rarely uses to anything near it's potential.

If the primary objective of a CRM system is to support the sales and administration teams, then why could it not be pro-active in actually identifying sales opportunities and alerting users to when customers started to drift away?

This is where Sales Intelligence (SI) was born, Vecta, one of the leading UK providers of SI solutions for example developed and implemented its first products during the late 90's.

Traditional CRM passively supports conventional sales techniques, often designed to drive 'new customer acquisition', but providing little in the way of delivering insight into the buying patterns of the all important existing customer base and so is unable to drive the sales effort.

It is designed to help salespeople record soft customer information, but it is much less effective for identifying new customers or retaining and selling more to existing ones.

A good Sales Intelligence system however will include advanced CRM style contact management functionality but will also extract the critical operational information it needs from existing back-office and accounting systems, which means there is no need to invest in an expensive CRM or BI solution.

It also avoids the long implementation period of traditional BI solutions that have to be built-to-order often by the user, and avoids the typical data 'overload' caused by the BI system when it is up and running.

Sales Intelligence is designed specifically around this premise that successful sales depend on identifying the right opportunities at the right time.

All the information needed to find new sales opportunities and identify customer issues is somewhere within your company's databases, and Sales Intelligence software simply automates the extraction of this knowledge and delivers it to the sales team.

Provided by vendors such as Vecta, it works by monitoring and analysing the buying patterns of customers by drawing data from existing accounts and enterprise software.

Irregularities and other trends in customer spending will trigger alerts that translate into sales leads delivered straight to the relevant sales representatives.

If, on the other hand, you need in-depth information to review and analyse business processes, then you may wish to purchase a full BI system.

Buyer beware, however, traditional BI solutions are seldom straightforward and users often have to build and implement systems themselves.

Similarly with CRM systems, salespeople are usually required to input data before they get useful information back, so end user adoption is far from guaranteed.

Put simply, all of these technologies are concerned with information management and, equally importantly, the every day use of that information.

Before considering any technology investment, it is vital that distributors identify the exact business requirement the promised information will meet.

Once this is established, they must not shy away from asking robust questions of all suppliers and mapping them against clearly deliverable business objectives.

Acronyms promise but fail to deliver

2006-12-28T03:56:00.000-08:00

Destroyed subcontractor wins with turning centres

2006-12-28T02:10:00.000-08:00

Subcontractor Colbree Precision was based within two hundred yards of the Buncefield depot and the blast destroyed its factory and most of its equipment.

When the Buncefield petrol storage facility in Hemel Hempstead exploded last December the effect on neighbouring companies was devastating. subcontractor Colbree Precision was based within a two hundred yards of the depot and the blast destroyed its factory and most of its equipment. But what could have been a complete disaster for the company has actually allowed it to develop new ways of working by investing in three new Nakamura-Tome turning centres from UK representative Turning Technologies.

As director Steve Bree explains, Colbree makes most of its smaller turned parts on bar fed sliding head machines, but before the fire it only had single spindle CNC machines for parts bigger than 32mm diameter.

Not only was Steve unhappy with their reliability, but they didn't fit in with his desire to cut out costly and time consuming multiple operations.

When the single spindle machines were destroyed in the fire Steve wasn't sorry to see them go.

'Although we lost that larger CNC capacity, we had already been looking round for alternatives - and in particular we were thinking of investing in Nakamura twin-spindle twin-turret lathes so that we could expand one hit machining,' he says.

'Obviously, in many ways we would have preferred it if the fire hadn't happened, but when it did we tried to make that work to our advantage as an opportunity to change the way we worked.' The Nakamura machines that Colbree invested in - two WT-150 turning centres and one Super NTJ - are all twin-spindle, twin-turret machines that allow complete components to be produced in one set up.

The WT150 machines have 51mm bar capacity, the Super NTJ has 65mm bar capacity.

All three machines are equipped with 24 tool stations per turret, including 12 driven powerful driven tool positions, and are designed to be highly precise, rigid, yet compact production machines.

The Super NTJ also has a +/- 90o B-axis on the upper turret.

This means that the parts can also be machined on multiple angled faces and contour milled in one set up during the turning cycle.

Colbree's major customers in sectors such medical equipment, defence, oil and aerospace often require complex parts with many auxiliary milled and drilled features, which had required further operations on machining centres.

With the new Nakamura machines these can easily be completed in one hit - and the B-axis on the Super NTJ opens up even more possibilities.

'With the B-axis we can actually swivel the turret round and do features such as angled holes.

The only way we could do this before was as another operation on a milling machine.

Doing it on the same machine as the turning obviously reduces the manufacturing time and maintains accuracy.

We used to have three milling machines and now we have cut that down to one - the more work you can do while you are turning the better,' says Steve Bree.

'With these new machines we can do things we couldn't do before and improve cycle times on the work we are already doing.

They have made us more competitive.' The speed with which Colbree has bounced back from what could have been a crippling blow has been impressive.

It was back in full production in new premises within eight weeks of the blast - thanks to good disaster recovery insurance and suppliers who were prepared to make an extra effort.

'Turning Technologies pulled out all the stops to help us back into production as quickly as possible.

They took a chance on our verbal order and were able to rescheduled and reallocate machines.

Irish subcontractor buys advanced turning centre

2006-12-27T02:09:00.001-08:00

Macro CNC sells a twin spindle, three-turret, 10-axis Miyano turning centre with 51mm bar capacity to Irish precision turned/milled components manufacturer, Mann Engineering.

The recent MACH exhibition at the Birmingham NEC proved the ideal opportunity for Mann Engineering of County Wexford, Ireland to become familiar with its new purchase - a Miyano ABX-51TH2 turning centre from Macro CNC. This twin spindle, three-turret, 10-axis Miyano turning centre with 51mm bar capacity has the manufacturing capability to produce complex/high-value parts efficiently in a single setup; the main reason behind the purchase. Mann Engineering specialises in the manufacture of precision turned/milled components for diverse industrial sectors.

Additionally the company designs and manufactures lathe bar feed systems and specialist tooling/fixturing systems for manufacturing applications.

A primary objective for the company will be market penetration into the highly competitive and demanding medical device sector.

Mann Engineering started purchasing CNC machine tools at MACH 2002 and has since acquired ten CNC machines, two of which are Miyano ABX-51TH2 machines.

Rolf Fuhrmann, managing director, commented: 'Since the introduction of the first Miyano, we have been able to produce parts in a single set-up with minimal labour involvement'.

'There are no second operations and this dramatically reduces cycle times when combined with increased product quality it enables the company to directly compete with off-shore competitors.' The first Miyano ABX-51TH2 was bought at MACH 2004 and was one of the first Miyano ABX machines sold in Europe.

The third turret on the machine has provided the company with sustainable productivity improvements in the order of 20%-30% and with such impressive results, it is no surprise the company has opted for a second machine.

The second Miyano ABX-51TH2 turn/mill centre was installed and commissioned the week after MACH 2006.

With this latest state-of-the-art machine the lower tooling turret, usually dedicated to the left spindle, can now be deployed on either spindle.

This additional manufacturing facility further enhances the manufacturing capability within the company and facilitates the company focus of providing cost-effective, high value added and high quality components to their expanding customer base.

With a solid order book and a customer base in excess of 50, the company sees investment in innovation and high specification machine tools, not only as the way forward but the only way to survive in such competitive times.

The commitment of Mann Engineering is summarised by John Stretton, general manager of Macro CNC: 'most subcontractors have a threshold and will work with 6- to 8-axis machines, but will go no further'.

'For Mann Engineering, like any other machine shop, it takes a massive leap of faith to invest in a 10-axis three turret fixed head machines.

For companies like Mann Engineering that are willing to take technology to the next level, the benefits can be remarkable.

This type of investment will enable Irish companies to level the playing field against cheaper foreign economies.' An example of this can be seen in the cycle time reductions at Mann Engineering.

One particular component previously taking 2 min 30s and four operations to complete is now being completed in 25s in a single operation.

Another job taking 20 minutes and five operations; it is now produced in 8 minutes complete on the Miyano ABX-51TH2.

Mann Engineering with the purchase of this additional Miyano ABX-51TH2 is proactively establishing itself.

The company fully realises the crucial role of CAD/CAM and co-ordinate measurement systems required to complement these CNC resources.

To address these issues the company has embarked on an InterTrade Ireland, Fusion graduate development programme in association with the University of Ulster, Belfast.

The primary objective of this cross-border programme will be to focus on business improvements, the integration of CAD/CAM systems and a CMM inspection facility.

'As a company we are committed to establishing continual productivity improvements.

Single hit machining and rapid changeovers together with the rigidity and additional power provided by the Miyano machines enables us to manufacture significantly more efficiently than any competitors in the Irish market.

We are at the forefront of technology and the acquisition of a second Miyano ABX-51TH2 at MACH 2006 will enable us to stay ahead of the competition,' concluded Fuhrmann.

Highly productive lathes' UK stocks increased

2006-12-27T02:08:00.000-08:00

Linear drives, 'high-end' controls and a novel tool box system in CNC universal lathes have stimulated demand, such that DMG (UK) is increasing machines in stock - including CNC millers.

To meet an increasing demand for its most popular machines on short lead times DMG (UK) has taken the unprecedented step of establishing a range of stock machines. These include both milling and turning machines and cover a wide range of performance requirements. In the CNC universal lathes category the options extend from the NEF 600 and CTX 10-series models through to the CTX 620 linear that provides up to 28% higher productivity thanks to the linear drive, high-end controls and a unique tool box system.

The single spindle Sprint monoBLOCK and twin spindle Twin turning machines are readily available as is the GMX400 linear for six-sided machining with up to 90mm bar capacity and 12,000 rev/min milling spindle.

The entry-level DMU 50, the DMU 60 and 80 monoBLOCK and DMU 50 eVolution linear models for five-sided/5-axis machining provide a wide choice of CNC universal milling machines.

And the choices continue with DMC-V vertical machining centres and models from the DMC U universal machining centre series with pallet changer for 5-axis machining.

All machines are available for immediate delivery and may also be supplied on an attractive rental or lease basis.

Their price includes full programming and operator training and delivery within the UK.

VTLs plus MCs provide wheel making flexibility

2006-12-26T22:27:00.000-08:00

Machining wheel carriers - or 'knuckles' - is performed on a very flexible 'quad-type' manufacturing system based on vertical turning centres, machining centres, automation and robotic handling.

The manufacturing solution for the machining of wheel carriers, also called 'knuckles', adopted by Georg Fischer Automotive, Singen in Germany, is a prime example of productivity and quality on the smallest possible footprint. This particular 'quad-type' Manufacturing System is the brainchild of a team of highly experienced specialists from GF, EMAG and SW. All parties expect that this will create a 'bandwagon' effect, bringing in further large-scale orders for everyone concerned.

* Summary of the manufacturing system for front axle wheel carriers/knuckles.

Linear automation equipment and robots link up four radially arranged, flexible manufacturing cells - consisting, in the main, of two each of EMAG VSC 500 turning centers and one each SW BA 600-2 horizontal, twin-spindle machining center, i e, in total eight VSC 500 and four BA 600-2 - with an industrial washing machine, measuring cells and inkjet markers, to provide 880m2 of concentrated productivity.

* The rivalry between cast iron and aluminium - the rivalry between cast iron and aluminium has not yet been brought to a conclusion.

Cast iron materials are still eminently suitable for the conversion of automotive ideas into reality - provided the partner in the production of such components has a firm grip on the material and the processes involved.

It is being confirmed again and again that the use of light alloys does not always lead to the necessary reduction in weight, and especially not when the attendant requirements also include cost benefits.

Cast iron, however, still carries a creative weight potential, especially if one keeps in mind the availability of innovative ferrous alloys such as higher-tensile ferritic materials.

GF Automotive - the automotive sector of the Georg Fischer Group with a global workforce of 14,000 and its headquarters in Schaffhausen, Switzerland - sees itself as a member of a partnership of excellence in the field of modern, cast iron-based vehicle manufacturing solutions.

Continuous research and development in the areas of pressure die, sand and chill casting in iron, aluminium and magnesium are the kind of activities that are in high demand in development- and manufacturing-based partnerships with the automotive industry.

It gives the makers of vehicles access to a whole range of materials and manufacturing solutions for ready-to-install components.

Within the Swiss Group, the plant at Singen in the South of Germany - with its close on 1,300 staff and an annual turnover of EUR 220 million - is responsible for the manufacture of ductile cast iron components for passenger cars and commercial vehicles at a ratio of 50:50.

The 180,000 tonnes of cast iron parts produced annually are used to make chassis, steering and transmission components and also motors, the major customers being the important European car manufacturers in both branches of the industry.

It therefore did not come as a surprise that GF Automotive, Singen, received the order for the casting and machining of the two front axle wheel carriers for the BMW 1 series and also for the new BMW 3 series.

The larger size is intended for the high-powered vehicles and the smaller one for the entry-level models.

Once the 'run-up' period for the models has been successfully negotiated, a total annual number of 450,000 sets is to be delivered to the assembly plants at Dingolfing and Leipzig in Germany and also in South Africa with a lead time of just two to three days.

The complex front axle wheel rim geometry and the resulting variety of machining geometries would normally be an ideal case for the clever experts in special purpose machine construction.

However, although special purpose machines are available for every single requirement these days, they are often quite inflexible - when one of today's most important investment criteria for production tools happens to be flexibility.

* More flexible than special purpose machines - the specially conceived manufacturing solution to the requirements at Singen consists of highly productive vertical turning centers from EMAG, Salach, and horizontal machining centers from SW, Waldmoessingen - today part of the EMAG Group, and represents a neat bit of straight-forward, uncomplicated, partnership-based work, offering a high degree of productivity on a compact footprint of just 880m2.

Four radially arranged manufacturing cells ensure flexibility, each of them consisting of the following.

* Two EMAG VSC 500 pick-up vertical turning centers with integrated measuring system, special chucks and automatic workpiece handling.

* A SW BA 600-2 twin-spindle horizontal machining center with 2x4 clamping unit on a 5-axis double swivel trunnion.

* A FANUC R 2000-i 165F industrial robot with a swivel gripper able to accommodate both types of wheel carriers.

* An inkjet writer with optical recognition, which marks each component with its specific ident number.

* A downstream industrial washing machine cleans and protects the wheel rims against corrosion.

Georg Fischer has invested some EUR 10 million in this ingenious manufacturing system.

The price also covers: the elaborate special workholding equipment, the original tooling specification and - last but by no means least - the extensive process know-how.

* About the companies involved - in 2004, the Georg Fischer Group, with its headquarters in Schaffhausen, Switzerland, and its 12,300 staff worldwide achieved a consolidated turnover of approximately EUR 2.3 billion, of which EUR 1.1 billion were generated by the automotive sector with its workforce of about 5,800.

The Singen works employ 1,300 staff, achieving a turnover of EUR 220 million.

Half of their annual production of 180,000 tonnes of ductile cast iron is used for passenger car parts and half for truck components.

20% of them are complete machined and dispatched ready-to-install, another 20% are pre-machined and 60% leave the works as raw-parts.

The EMAG Group, with its headquarters at Salach, Germany, presently employs 2,000 staff, with a turnover of approximately EUR 430 million in 2005.

The Group includes the grinding specialists Reinecker (high precision internal grinding), Karstens (external production grinding), Kopp (grinding of cams and camschafts) and Naxos-Union (grinding of crankshafts), the laser specialist Lasertec and the automation equipment manufacturer Heilig.

Since mid-2004 SW Schwaebische Werkzeugmaschinen, Schramberg-Waldmoessingen/Germany (horizontal and vertical machining centers), with 265 staff and a turnover of EUR 70 million is also part of the EMAG family.

Since May 2005 the Group also includes the gear hobbing specialist Koepfer.

* Manufacturing system - comments - 'A technical availability of 95% for the complete system makes us very happy,' commented Jurgen Bolle, responsible for production planning and complete machining.

'We also reach the calculated efficiency level of 80% without any problem.

In fact, we are achieving an effective level of 85%,' he added with a smile.

Norbert Schnurr, the responsible project leader, asked the two machine manufacturers for a cycle time guarantee.

'It has since been more than just adhered to.

The system is highly flexible - not only with regard to changing batch sizes, but also when it becomes necessary to react quickly to component variations and new orders.' He also praised the excellent co-operation throughout the lifetime of the project between GF and BMW on the one side and the two machine tool builders, EMAG and SW, on the other.

* 19 shifts/week - owing to the fact that the BMW series 1 and 3 are in greater demand than expected, the plant is running to capacity.

In fact, it presently works 19 shifts a week - from Sunday evening to Saturday afternoon.

The total capacity of 450,000 sets of wheel carriers means that between 1,200 and 1,400 sets - or 56 skeleton containers full - are leaving for the BMW sites every day.

The blanks of the wheel carriers/knuckles, cast and protective-coated at Singen, are inserted into the workpiece receptors of the transport system and conveyed to the the VSCs.

One of the two VSCs within the four manufacturing cells complete-turns the wheel hub and mills, drills and threads the fixing points of the left wheel carrier, the second VSC the right wheel carrier, respectively.

Every fourth component is measured with in-process gauging equipment and, like the other three, inserted by robot into the SW twin-spindle machining center, where the linking points are high-precision milled and drilled.

The components are then washed and all crucial features and dimensions re-checked to intolerances on a central measuring cell.

Finally, an optically controlled printer marks every component with an identifying code.

To ensure that such large quantities of components are delivered on time and at the right batch sizes is not just a question of machine performance but also of organisational effort.

For this reason, a cell computer with SAP system is used to handle all communications and necessary data exchanges.

GF sees the performance, economic viability and perfection of this manufacturing system as the Group's successful entry into the mass production of completely-machined vehicular components.

Together with their acquired know-how in manufacturing techniques this surely provides GF with a decisive edge in the global cut-throat cost and quality competition of 'made in Germany' production components.

CNC machine tool update doubles output

2006-12-26T22:26:00.000-08:00

As a subcontractor replaced its early CNC machine tools, the same floor space created twice the number of components - a productivity increase that soon balanced out any price differential.

Investment has always been a high priority for the Harmon Group, a family-owned business founded in 1964 as Harmon Form Tools. Initially the company provided a grinding and tooling service, now known as the Harmon Precision Grinding division, with the focus on the aerospace and defence industries. But in 1987 it entered the sub-contract machining market with the formation of the Harmon Manufacturing division and in 2002 set up the Harmon Metal Treatments division.

All three divisions are located in 32,000ft2 purpose-built premises on the Ferndown Industrial Estate in Wimborne, Dorset, each functioning as a separate business entity accessing shared resources and looking to lean manufacture as the route to remaining competitive in a global marketplace.

As part of its lean manufacturing strategy the 76-employee Harmon Group has recently re-organised its machine shop into four manufacturing cells and added to its complement of Mazak CNC lathes and machining centres with a QuickTurn Nexus 350 MY turning centre.

According to Robert Harmon, group managing director, the decision to take the tally of Mazak machines to 12 was a relatively easy one to make, because of the performance of the existing Mazak machines and the QuickTurn Nexus turning centre's combination of advanced technology, productivity and value for money.

'The Mazak machines are very reliable and in terms of components per hour the output is phenomenal,' saidHarmon.

'As we replaced our early CNC machines with Mazaks, we found that the same floor space was, in effect, creating twice the number of components and this increase in productivity soon balances out any price differential.' However, finding and retaining skilled staff to operate these CNC machine tools is a tougher proposition, although the problem is tackled in typically enterprising fashion.

In addition to encouraging several third-generation family members to enter the business and to follow in the footsteps of Robert Harmon and his brothers, David and Ian, by beginning as apprentices, the Harmon Group has made the most of the switch to the new manufacturing cell layout.

Said Harmon: 'As we set up the next cell of three machines, one of the operators from the previous cell moved to the new cell, allowing us to move a semi-skilled operator to the first cell and then to bring his level of competence up to that of a fully skilled operator.

This has proved to be an extremely efficient way to increase our level of multi-skilled staff and to enable us to continue expanding our business.' This willingness to adapt to new ways of working has enabled Harmon Manufacturing to develop an enviable reputation for its ability to machine intricate components while, at the same time, reducing costs and lead times for a customer base that includes 'preferred supplier status' with Airbus Industrie, BAE Systems, Westland, Goodrich and Smiths Aerospace.

'We do not do easy components,' said Harmon.

'We do high value, complex components and we are very good at what we do.

However, close tolerance aerospace components such as undercarriage legs, actuators and hydraulic cylinders can take several weeks to complete and it is essential to keep track of work-in-progress to ensure on-time delivery.' Part of Harmon's expertise rests with the use of Preactor scheduling software, the basis for one of the four modules in Mazak's Cyber Production Centre (CPC) production management system.

'We now know exactly how our shopfloor capacity is loaded and we have the flexibility to schedule AOG (aircraft on ground) priorities without adversely affecting other work.' Harmon Manufacturing has an annual turnover of around GBP 5 million but current plans envisage this rising to GBP 15 million within the next few years.

And with its extensive experience of machining unusual or exotic materials such as plastics, heat treated stainless steels, Inconel, Monel and Hastelloy, ISO 9002-accredited Harmon is well placed to advise potential customers on methods of manufacture, whether small batch work or large production runs.

'Anyone sitting back and waiting for new business to come to them will not survive,' said Harmon.

'However, we are not looking just to the UK for future growth.

We are looking to companies in France and Italy, for example, that are associated with our existing customers and where existing customer approvals are relevant.

The key attributes are quality and delivery, and maintaining delivery schedules is one of the reasons why we set up Harmon Metal Treatments, because when we were sending out components for treatment we were unable to guarantee their return delivery time.' The QuickTurn Nexus 350 MY chosen by Harmon Manufacturing features a 30kW/3300 rev/min spindle, and can machine components up to 420mm diameter by up to 1538mm long.

It also benefits from the inclusion of a NC electric tailstock that delivers quick set-up with no manual intervention.

The tailstock provides accurate support even for components that can only be supported by low-thrust force.

Added versatility is provided by the 150mm Y-axis and the capability of rotary tools in any of the 12 positions on the drum-type turret.

These tools are driven by an impressive 7.5kW/4000 rev/min motor.

Machine power is matched by agility, with the X, Y and Z axes having rapid traverse rates of 30m/min, 15m/min and 25m/min respectively.

This fast, vibration-free, acceleration/deceleration results from the use of high-gain servo-control and high-power AC servo motors.

The Mazatrol Fusion 640T Nexus CNC unit features the easy-to-use Mazatrol conversational programming format.

Mill-turn centre machines parts in 'one-hit'

2006-12-25T01:27:00.000-08:00

The main attractions of a mill-turn centre to a precision engineering company was its ability to enable parts to be made in 'one-hit', reduced time spent on job set-ups and reduced cycle times.

Chard, UK-based precision engineering subcontract specialist - Metaltech Precision - has recently invested in a Doosan Daewoo MX 2500 ST mill-turn centre. The investment, the latest in a long line of machine tools purchased from Leamington-based Mills Manufacturing Technology - is already having a positive impact on Metaltech's productivity and performance by reducing cycle times, increasing work throughput and improving part accuracy. Metaltech is one of the largest precision subcontractors in the South West.

The company currently employs 55 people at its 35,000ft2 facility (soon to be increased by a further 5,000ft2) and operates 24h, 'around-the-clock' production (Monday - Friday).

Metaltech manufactures and supplies precision components (predominantly high-accuracy pump and valve parts and sub-assemblies) to a diverse range of industry sectors.

These include - petrochemical, oil/gas, tobacco and other 'processing' industries.

The company provides total manufacturing solutions to its customers - and as well as the full complement of CNC machining capabilities - turning, milling, grinding etc - also offers fabrication and welding as well as other finishing operations, e g, painting, heat treatment, shot-blasting, assembly, etc Metaltech manufactures high-precision parts made from titanium, aluminium, mild steel, alloy steels, Inconel, Hastelloy and stainless steels (e g, 316, Duplex, etc).

Parts are usually required in low-medium volume (typically 100 off) - although the company does manufacture in batch sizes from 1-5000 off.

Part accuracy varies according to the specific job in question - but on average +/-7-8 micron tolerance is standard.

The company's latest investment in the Doosan Daewoo MX 2500 ST Mill/Turn machine reflects Metaltech's desire to increase its productivity and maintain its competitive advantage.

The MX machine provides Metaltech with improved manufacturing flexibility - from simple turning operations right through to highly complex multi-axis machining.

Whatever the manufacturing scenario - the MX 2500 is a more than capable performer.

The attraction of the MX machine to Metaltech was its ability to enable parts to be made in 'one-hit'.

The advantages of 'one-hit' machining are well known - and Metaltech is experiencing and benefiting from all of them.

Reduced time spent on job set-ups is a definite advantage as are reduced cycle times.

Improved part accuracy (due to minimal workholding and fixturing) and reduced operator intervention - also have a positive impact on performance.

Said Steve Hill, director at Metaltech: 'The decision to invest in the MX 2500 ST was a relatively easy decision to make.

Although the machine represents a significant investment for us - we know that its functionality and capability will strengthen our performance.

Even though we have only had the machine for a couple of months - it is already an indispensable part of our operation'.

The MX 2500 ST is a high-performance machine.

It has a 76mm bar working capacity and both left and right (main) motor driven spindles have 26kW 3,500 rev/min capability.

For extra productivity the MX machine has a 18.5kW 10,000 milling spindle with 40 tool magazine (B-axis with 240 deg indexing); a +/-80mm double-slide Y-axis and a 12-station driven tool bottom turret.

Multi-function 6-axis turning centre has Y-axis

2006-12-25T01:26:00.000-08:00

A multi-functional 6-axis turning centre offering heavy-duty cutting capability and high levels of accuracy has two spindles radially synchronised to provide accurate second operation milling.

In today's global economy precision manufacturers expect and demand more from their machine tools. Manufacturers need to achieve better machine utilisation to help increase work throughput, reduce production bottlenecks and improve lead times. They need machines that are capable of multi-tasking in order to increase their production capabilities and capacity - and reduce operator interventions.

And they need machines that deliver increased accuracy and repeatability, whilst offering a high level of reliability.

As a consequence more and more manufacturers are looking to invest in multi-functional machines to help them achieve these business benefits.

And more and more of these manufacturers are specifying, and relying on, Doosan Daewoo machine tool technology to help improve their competitiveness.

The Puma 2000SY is a multi-functional 6-axis turning centre designed for a multitude of machining applications (heavy-duty cutting capability and high levels of accuracy).

The machine has a powerful, high torque 15kW 4,500 rev/min main spindle with 65mm bar capacity, and a 7.5kW 6,000 rev/min sub-spindle with full C-axis control and 0.001 deg indexing.

Both spindles are radially synchronised to provide accurate machining of second operation milling operations.

The versatility of the 2000SY is increased via the machine's generous 100mm travel Y-axis function - which enables parts to be machined off centre, such as contour milling of keyways and cross milling of flats.

The 2000SY combines flexibility and power with speed.

X and Z-axis rapids are 20m/min and 24m/min respectively, and the machine's large, 12-station, heavy-duty turret achieves 0.10 second indexing - which helps reduce machine cycle times still further.

The 2000SY has a rigid design structure.

Its heavy-ribbed, torque tube cast iron construction absorbs vibration and helps reduce thermal distortion and the machine's guideways are widely-spaced and of a wrap-around type for increased rigidity and life-time accuracy.

To improve the machine's performance the 2000SY features the latest milling toolholder design with Eppinger Preci-flex face and taper contact system that delivers higher rigidity and, as a consequence, improved milling performance.

The Puma 2000SY also includes as standard an automatic parts catcher and automatic tool setter.

CNC investment strategy pays well

2006-12-24T01:26:00.000-08:00

Precision engineering subcontractor's continued growth is down to rigorous planning, a disciplined focus and strategic investment in advanced machine tool technology.

Market-leading Poole-based specialist subcontractor - Aercomp Precision Engineering - is experiencing significant growth and has done so since its creation 8 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 two years ago to its present 8,000sft2 facility - and why the company operates a 5-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 3 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 rapid feeds.

* 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 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.''

Twin-spindle CNC slant bed lathe has Y axes

2006-12-24T01:25:00.000-08:00

With C and Y axes plus 12 driven tools, a twin-spindle CNC slant bed lathe has X, Y, Z axes travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B axis (right-hand spindle).

The comprehensive range of turning machines offered exclusively in the UK by Ward CNC of Sheffield includes a series of high-specification yet cost-competitive Takisawa Taiwan lathes with functionality and specifications that illustrate how the machines offer 'Japanese quality at Taiwanese prices'. Takisawa Taiwan machines utilise a special one-piece, thermally balanced bed that promotes powerful and stable operation, coupled with four-track super rigid precision linear guideways and high-speed servo turrets. Fanuc 18i or 21iT CNC feature as standard, incorporating the user-friendly Manual Guide i programming functionality.

With C and Y axes plus 12 driven tools, the Takisawa Taiwan EX-910 twin-spindle CNC slant bed lathe has X, Y, Z axes travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B axis (right-hand spindle).

It features full C axis capability on both spindles, and accommodates bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement maximum turning diameter and length capabilities of 340mm and 660mm.

Both left- and right-hand spindles incorporate oil-cooled Fanuc built-in motor providing exceptional performance for turning and C-axis operations.

Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.

Driven tool speed is 4000 rev/min from a 5.5kW motor.

Rapid traverse rates are 24m/min.

As standard, the machine is supplied with auto tool setting arm, parts catcher and swarf conveyor.

Bar feed systems and collet chucks are options.

With a swing over the bed of 400mm, the Takisawa Taiwan EX-108 has a crosslide travel of 320mm and a between centres distance of 645mm.

Standard turning diameter is 216mm, and with a 203mm chuck the machine has a maximum turning diameter and length of 320mm and 530mm, respectively.

Bar capacity is 52mm and spindle speeds range from 60-4,000 rev/min (7.5/11kW) for the 12-tool turret machine.

Auto tool setting arm, parts catcher, swarf conveyor and programmable quill tailstock are standard; collet chucks and bar feed systems are options.

With C-axis and 12 driven tools, the Taiwan Takisawa EX-310 three-axis slant bed CNC lathe offers users a level of single set-up turn/mill/drill capability that is unparalleled on a cost-to-performance basis.

Swing over the bed is 495mm, between centres distance is 845mm and the maximum turning diameter and length is 350mm and 710mm, respectively.

The 75mm bar capacity machine has rapids of 20/24m/min and a spindle speed up to 3,500 rev/min from the Fanuc 15/22kW oil-cooled built-in motor providing exceptional performance for turning and C axis operations.

Driven tools speeds are 40-4,000 rev/min.

Auto tool setting arm, parts catcher and swarf conveyor are standard, and the use of the optional auto toolsetter, bar feed and robot interface systems can significantly enhance the machine's capability for the unmanned production of complex parts.

Fanuc 21iT CNC incorporating the user-friendly Manual Guide i programming functionality is standard.

The heavy-duty Takisawa Taiwan EX-122 CNC lathe is of cast iron slant bed construction combined with extra heavy duty linear guideway technology.

The long bed EX-122 universal has maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min.

(The EX-122/H variant also available offers a 30/37kW main motor, which coupled with the standard two-range geared headstock offers excellent power and torque capabilities.) The EX-122 has a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330mm and 1650mm, respectively, and a 200mm spindle bore.

Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.

Fanuc 21iT CNC incorporating the user-friendly Manual Guide i programming functionality, auto tool setting arm, bar feed interface and swarf conveyor are all supplied as standard; bar feed systems and steady rests are optional extras.

CNC lathe choice mirrors subcontractor's success

2006-12-23T01:24:00.002-08:00

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.'

CNC turning centre has extremely stiff Y-axis

2006-12-23T01:24:00.001-08:00

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.

Oil/gas products firm relies on latest CNC lathes

2006-12-22T01:23:00.000-08:00

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.''

CNC lathe and machining center combined in one

2006-12-21T01:35:00.000-08:00

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.

Turning centre deploys 80 tools without a magazine

2006-12-21T01:22:00.000-08:00

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 vertical CNC lathe machines shafts

2006-12-20T01:35:00.000-08:00

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.

Measuring microscopes for industrial inspection

2006-12-20T01:21:00.000-08:00

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.

Vertical turning capacity increased to 340mm dia

2006-12-19T01:34:00.001-08:00

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 centres completely machine parts

2006-12-19T01:33:00.001-08:00

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.

Machining raw-part to complete-machined shaft

2006-12-18T01:32:00.000-08:00

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.

Compact turning centre raises productivity

2006-12-18T01:31:00.000-08:00

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.'

CNC multi-function lathes replace cam automatics

2006-12-17T23:29:00.000-08:00

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.'

Multi-function turning centre goes on show

2006-12-17T03:01:00.000-08:00

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.

Complete automatic inspection systems

2006-12-16T02:59:00.000-08:00

Olympus has introduced the first system in its analySIS Inspector Series of complete automatic inspection systems for specific applications.

Olympus has introduced the first system in its analySIS Inspector Series of complete automatic inspection systems for specific applications. Based on the newly launched analySIS family of software solutions, the analySIS Inspector series has been designed to fully automate and solve very specific tasks, such as filter, cast iron, and non metallic inclusion inspection. analysis software with hardware components, including microscope, digital camera, motorised stage and controller, all make up these new complete automatic inspection systems.

Incorporating a specially designed Graphical User Interface (GUI), the Inspector series' push-button operation is highly efficient and makes difficult analyses very simple to conduct and complete successfully.

The software is user-friendly and guides the user step-by-step through the entire analysis procedure.

Few steps are involved and more complex analyses can be learnt quickly.

The first system launched in this new series is the analySIS FilterInspector for simple fully automated optical analysis, classification and documentation of filter residues.

This is ideal for processes which must conform to certain cleanliness standards, such as during engine piston manufacture.

With its high resolution, the analySIS FilterInspector is designed for fast analysis.

This means that full inspection of circular filters 47 mm in diameter may be conducted quickly and at resolutions down to 0.8 um.

This speed is possible due to the fast cameras and motorised stages included in the comprehensive system solution.

The precisely attuned Olympus hardware and software components used in the Inspector series yield results with far greater precision and reproducibility than would be feasible using conventional systems.

Furthermore, as 'open' systems, the Inspector series components can be used as a standard microscope set-up for alternative applications, if required.

This also makes the Inspector series a highly flexible tool, which is a key requirement for Research and Development facilities.

Mill-turn centre has rapid-motion feeds

2006-12-16T02:58:00.001-08:00

Mill-turn centre has very stiff Y-axis A high-performance mill-turn centre features an extremely stiff Y-axis featuring wide-set guide rails and also very fast rapid-motion speeds.

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 effective. A very special highlight of the new Maxxturn 45 is the Y-axis. It has been integrated into the machine structure and stands on extremely wide-set guide rails.

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

Additionally, the machine has a very 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 control unit - SHOPTURN or Manual Guide are standard equipment.

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

There is a Swing Loader for automatic loading and feeding out.

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

The latter is on offer in a package with the Maxxturn 45 at an unbeatable discount price.

Machine details include the following.

* Maximum bar diameter - 45mm.

* Maximum part length - 480mm.

* Maximum part diameter - 300mm.

* Travel in X/Z/Y - 160/510/ +40/-30mm.

* Maximum lining diameter HS/GS - 200/130mm.

* Speed HS/GS - 6300/6300 rev/min.

* Power HS/GS - 13/6kW.

* Tool turret - 12x VDI25.

* Number of tool positions - 12x.

* Rapid motion speed X/Z/Y - 24/30/10m/min.

Small turning centre gives power and precision

2006-12-15T02:58:00.000-08:00

Turning centre with a 25mm bar capacity and 405mm between centres offers very small footprint, a very solid machine bed, a thermo-symmetrical headstock with a precision spindle bearing.

At the AMB in Stuttgart, Germany, Emco Maier will unveil its new CNC E25 turning centre for the first time. This machine represents an impressive rounding off at the 'bottom end' of the model scale of the successful E range from Emco. The E25 with a spindle bore of 25mm will be the successor to the popular Emcoturn 325 in the Emco portfolio.

However, the new E25 is anything but just a mere updated version of its predecessor.

Whilst holding to the maxim 'design to cost', which is adhered to for the whole E range, the E25 is a completely new development.

The aim of the development work was an ambitious one: improving the performance, quality and precision at the same time as radically reducing costs.

The first tests have shown that the Emco developers have managed to achieve what the international market expects of the new E25.

The machine offers uncompromising quality levels right down to the last screw - and all this at an unbeatable price.

The standard version of the E25 costs only EUR 39.990.

For their money, customers will get the very best in European technology, with precision, a long service life and an excellent performance.

Emco is expecting a similar run on the E25 as it experienced with its sister model: 'Since we managed to match the low-cost offerings from the Far East with the E45 and E65 in terms of price and performance, many of our customers have been waiting for the continuation of the E range into the compact class,' said Emco's 'upbeat' product manager Gerhard Meisl.

* Impressive technology - the E25 will be available in four different variants - starting with the basic version and including the tailstock version as well as the top-of-the-range model with driven tools and a C axle.

All of the variants are equipped with a 12-head turret with VDI 16 shaft.

The E25, with its very small footprint, offers everything that is good about and expensive in modern machine tool building: a very solid machine bed made from machine casting, a thermo-symmetrical headstock with a precision spindle bearing, pre-stressed roller guides in all of its axles and a fast switching Sauter tool turret.

The customer can choose between a Sinumerik 810D and a Fanuc 0iTC control unit - including dialog programming with ShopTurn or ManualGuide.

And if anybody needs any more convincing about the Emco E25, then they should know that it offers a perfectly aligned bar loader package, that costs just EUR 8.950, inclusive of an alarm lamp and interface.

And any user that needs to feed the E25 with longer bars, will be very pleased to hear about the new Emco Top Load 4-25/3300 bar loader for 3m bars.

Fast facts about the Emco Emcoturn E25 include the following.

* chuck size 25mm.

* Center distance 405mm.

* Speed up to 6300 rev/min.

* Main drive power 5,5kW.

* 12 tool stations, VDI16.

* Six Stations for powered tools.

* About Emco - Emco the Salzburg, Austria, mechanical-engineering company, counts among the leading machine-tool producers in Europe.

Innovative products, high manufacturing quality and attractive design are the essential factors of success of the company that operates in the fields of smart CNC technologies as well as education and training systems.

Emco is part of A-TEC Industries group and currently employs a staff of about 1,000 personnel at six production sites in Austria, Germany, Italy and the Czech Republic.

Mill-turn flexibility frees up machining centres

2006-12-15T02:57:00.000-08:00

The flexibility offered by a mill-turn centre has enabled a machinist of complex parts to review methods and transfer work from machining centres and reduce cycle times.

Addmore Engineering has built a reputation for manufacturing complex and difficult to machine components to the highest standards of quality and precision. As a subcontractor it produces a wide variety of parts, including spinal implants for medical applications, hydraulic valves for earthmoving equipment and couplings for the oil industry. Frank Vasquez, proprietor of the company, is a committed entrepreneur and has formed and run a series of successful engineering companies, including Kelgate Engineering, which specialises in the manufacture of caliper braking systems for competition karts.

Kelgate brakes have an enviable reputation in the racing world, and out of the 35 runners in 2006 Le Mans 24h Pro Kart Enduro race, 26 were fitted with Kelgate equipment.

Furthermore, the winners in each of the three race categories, 100cc, 125cc Rotax and Biland all used its braking systems.

The complexity of the brake components led the company to re-evaluate its manufacturing methods in order to cut costs and speed up production.

Vasquez and Rob Dewar - managing director of Addmore - chose to install a Mori Seiki NL2500 SY 6-axis lathe with driven tooling and Y-axis, at the Addmore Engineering factory in Stewartby, UK.

Vasquez commented, 'Previously some of our components required six operations.

With the Mori Seiki we were able to reduce this to one.

The innovative milling capability of the machine is unique.

The direct drive in the spindle gives it more power than other mill/turn machines.

Additionally, it is competitively priced and we can achieve extreme quality.

On one part we reduced the cycle time from 1.25h to 15 min.' Reducing the number of operations has generated further advantages as less handling and resetting of the job has reduced the chance of introducing errors between operations.

'With one operation we can immediately see if the job is right.

With multiple operations an error may not be detected until several parts have been partially manufactured.

We are finding that components manufactured on the Mori Seiki are spot on,' he continued.

The Mori Seiki NL2500 SY achieves its accuracy through the rigidity of its construction and active measures to reduce vibration and thermal distortion.

This has been arrived at by static and dynamic analysis of the frame construction, which exclusively uses Japanese manufactured castings; the use of direct drive motors in the turret; and measures to control heat dissipation including oil cooling jackets around the spindle, milling turret and ball screw bearings.

Vasquez added, 'You can see how stable the machine is just from its weight.

We are very pleased with it and have just purchased a second to increase our capacity.' The machines will feed 80mm bar, and have been used to cut parts up to 380mm diameter in the chuck and, thanks to their rigidity, the company finds it easier to machine difficult materials such as Duplex, NiBRON and Marinel 220.

Once the first machine had been installed, Addmore's existing customers realised the possibilities for their components.

One customer has now subcontracted parts to the company which it previously made itself, due to the quality problems it experienced with previous subcontractors.

Vasquez said, 'We have experienced a 20% increase in business as a direct result of installing the two Mori Seiki machines.' The flexibility offered by the new machines has enabled Addmore to examine how it manufactures existing components.

It has been able to transfer significant amounts of work from its machining centres onto the Mori Seiki NL2500 SY's as a direct result of their spindle power and machining envelope.

The change has released extra dedicated milling capacity which the company has already filled up.

Addmore Engineering and Kelgate Engineering both operate at the top end of the quality spectrum, and for them the reliability, rigidity, and accuracy of the Mori Seiki NL2500 SY perfectly matches their philosophy of excellence.

Frank Vasquez concluded, 'Our investment in Mori Seiki machines has been a very good decision.

We have achieved some valuable cost reductions and added considerably to our turnover and profit whilst maintaining our high quality standards.' * About Mori Seiki (UK) - Mori Seiki UK, the UK arm of Mori Seiki Co, services and supports Mori Seiki and Hitachi Seiki machines in the UK market.

Mori Seiki is one of the world's leading manufacturers of metal cutting machines.

With its head office in Nagoya Japan, it employs 3,800 people, and is committed to innovation, quality, and service, with a range of machines to cover all industry sectors.

Machine tool specialist bought by management

2006-12-14T02:56:00.000-08:00

The Directors of Leamington-based machine tool specialist, Mills Manufacturing Technology, have successfully completed the management buy-out of the company which was first established in 1998.

The Directors of Leamington-based machine tool specialist, Mills Manufacturing Technology , have successfully completed the management buy-out of the company which was first established in 1998. Under the new arrangement which secures 100% of the equity, Mike Jenkins becomes the Chairman, whilst retaining his position as Managing Director. He is joined by fellow Directors and shareholders - Andrew Jack, Nick Frampton and Nav Ahluwalia - who, collectively, form the senior management team and are responsible for the future strategic direction of the company.

Funding to facilitate the exit of Close Investment has been provided by Barclays Leveraged Finance, supported by significant personal investment from the Directors.

Dave Davies, manager within Barclays, commented: 'We are delighted to have been able to support the management team in taking this significant step in the development of their business.

We look forward to working with the new owners as they continue to cement their market-leading position in the UK machine tools market.' Says Mike Jenkins: 'This is fantastic news for our staff and for our customers.

Our business is looking good for the future.

We have the funding, the resources and the people in place - and our sales performance, once again, is well ahead of the market.

Whilst it's certainly a case of 'business as usual' for customers and staff - we have exciting plans to grow the company in the future and are confident about our success.' The deal, finalised October 13th 2006, sees Close Investment - the Venture Capitalist who originally provided the finance for the management team to acquire the business - end its relationship with the company after 8 highly-successful years.

Mills Manufacturing Technology is the fastest-growing machine tool company in the UK.

The company has enjoyed consistent growth over a sustained period of time - and in the last 3 years has seen its sales rocket by more than 40%.

Mill-turn centre has B-axis for complex work

2006-12-14T02:55:00.000-08:00

A specialist sub-contract machinist has installed a a B-axis mill-turn centre to extend considerably the complexity of in-cycle prismatic machining that may be carried out.

Specialist contract machinist, PG Technology, has installed a B-axis mill-turn centre at its factory in Mitcham, Surrey. Supplied by NCMT, the Okuma Multus B300-W is the first twin-spindle mill-turn lathe on site and increases the contract machinist's turning capacity to 630mm diameter by 900mm long. It also extends considerably the complexity of in-cycle prismatic machining that may be carried out.

Business development manager, Clive Evans, stated, 'The addition of the Okuma machine to our existing, high quality CNC turning department will give the company a strong competitive edge in the UK and Continental European market place.' He added: 'With the Multus, we can make in one operation components that are normally machined in three to four ops.

So we are able to be even more competitive in delivering the right price for our customers, with which we have built up excellent working relationships based on high quality and rapid delivery.' Evans recently mentioned an aircraft hydraulics component in stainless steel that was previously quoted at GBP 118 and which could now be supplied for GBP 85.

There is a good chance that PG Technology will win this work next time around.

Another mill-turn job that will shortly take advantage of the 11kW milling spindle on the Multus is a stainless steel, eccentric cylindrical component that currently needs four operations on a lathe and a machining centre.

It will be machined in two operations and to very high accuracy, the position of some drilled holes being tied up to 3 microns relative to the bore centreline.

Installed at the end of August 2006, the Multus was first used for pure turning applications to give the operators a chance to familiarise themselves with the Okuma OSP P200L control and the machine's 7-axis CNC technology - X, Z, Y, B, C1, C2 and W (longitudinal travel of the opposed spindle).

On these jobs, the combination of the 15kW turning spindle, HSK A-63 tooling, 40m/min rapid traverse in X and Z and synchronous pick-up by the opposed spindle has on average allowed PG Technology to halve both the number of separate operations and manufacturing times, according to Evans.

Vincent Bootes, owner of PG Technology, commented, 'I am delighted to support the company with substantial new investment in the latest technology when I see the enthusiasm and commitment of the business to progress and strive for the ultimate accolade of world class supplier.' Concurrent with the new mill-turn centre installation, PG Technology purchased several seats of EdgeCam software, version 11, from Pathtrace to generate complex cutter paths.

A further development will be relocation of the factory in the first quarter of 2007 to new freehold premises nearby in Mitcham.

This will see the present 24h, 5 days/week operation go to 24/7 working, subject to recruitment of extra skilled people, which Evans complained is always a challenge.

He concluded, 'The Okuma Multus has already strengthened production of rotational components.

It brings turning in line with the highly advanced machining centre capacity we have, which includes full 5-axis capability.' 'The only way to compete these days is to invest in modern, capable production equipment like the Okuma Multus and it does not stop there, as we are currently looking into another 5-axis milling centre.

It will help in our goal to become the best supplier in the UK of machined parts, on time and to the right quality.

'One-hit' entry-level sliding head auto launched

2006-12-13T23:44:00.001-08:00

To be launched at MACH 2004 is a competitively priced, entry level 16mm capacity CNC sliding headstock automatic lathe offering highly productive 'one-hit' mill/turning of small parts.

Launching its competitively priced, entry level 16mm capacity CNC sliding headstock automatic lathe, Citizen has established a new benchmark for high productivity 'one-hit' mill/turning of small parts. Now available from NC Engineering of Watford, the Citizen C16-VIE features a yoke style tooling arrangement around the main spindle. This short movement, fast positioning design incorporates a gang post holding six turning tools, three driven tools and a high precision, four station toolpost.

This toolpost can present up to eight tools allowing machining operations to be carried out simultaneously at both the main and secondary spindles.

The higher level of flexibility gained from the new tooling layout is an important factor in expanding the capability of the machine to deliver a high productivity to investment ratio.

This is capitalised by Citizen's latest CNC control with its high speed central processor and macros which enable up to 20 per cent to be chopped from existing proven Citizen programs and machining cycles against the previous entry level B-series sliding head machine.

Also, influencing the price advantage of the C16-VIE is recent favourable currency movements and Citizen Machinery's development of its 'Supply Chain Management' philosophy in Japan which is able to significantly shorten production lead time and costs.

The built-in 16 mm main spindle has a 10,000 revs/min drive, full C-axis positioning as standard and a 200mm headstock stroke.

However, as a 1,000 (pounds sterling) option its capacity can be extended to 18 mm diameter.

The secondary spindle, which is also of built-in design, has the same 10,000 revs/min capability and full C-axis positioning is available as an option.

A feature of the gang toolpost is the incorporation of a motor-synchronised guide bushing with six tools configured for outside diameter turning.

In addition, three 8,000 revs/min driven tools with simultaneous high speed rigid tapping are available to produce external component features.

The new four station toolpost arrangement which has bi-directional sleeves is able to perform front and back drilling and tapping cycles simultaneously on a component at the main and secondary spindles.

Six spindle CNC multi extends back machining scope

2006-12-13T23:44:00.000-08:00

Six-spindle CNC mill-turning centre offers faster and significantly extended, simultaneous back-working compared with other multi-spindle auto's on the market.

A new, six-spindle mill-turning centre from Index, designated MS18C, will be launched in the UK by sole agent, Geo Kingsbury, at its open house in Gosport, 6th to 8th July 2004. The machine offers faster and significantly extended, simultaneous back-working compared with other multi-spindle auto's on the market. This has been achieved using a synchronous pick-up spindle that presents the parted-off component to four driven or static tools positioned well away from the area of the drum, finally depositing the finished part onto a conveyor.

The kinematically-driven pick-up spindle, with the option of a second, incorporates a 320mm Y-axis for machining off-centre features in addition to having a C-axis, 120mm of travel in X and 85mm in Z.

Conventional CNC multi's with opposed spindles have a restricted number of back-working tools which can move in no more than two axes.

In common with the manufacturer's other multi's, the new CNC machine has the ability to optimise feed rates and cutting speeds at each 11.5kW/10,000 rpm spindle, avoiding compromised machining conditions and so maximising productivity as well as tool life.

The MS18C is therefore ideal for economical, large and small batch production of components up to 18mm diameter from bar, including in materials such as high temperature alloys that previously could not easily be machined on a multi.

Front-end machining versatility is high owing to the ability to OD and ID turn, cross machine with driven tools in conjunction with the C-axis at each position, and optionally carry out gear hobbing and polygon turning.

There are 11 single- or two-axis CNC slides, the latter allowing both longitudinal and cross machining, so it is not necessary to allocate a slide for one or other operation.

Control is by the Index C200-4D, a derivative of the Siemens 840D which is easy to program on the shop floor and automatically performs collision checking for the pick-up spindle(s).

Comprehensive diagnostics for the machine and control are included, and it is possible to specify tool monitoring and a teleservice connection to an Index engineer for troubleshooting.

The machine may alternatively be programmed remotely on a PC running System 200 software, which accepts CAD input and has a DNC interface.

Up to 10 unmanned CNC lathes monitored remotely

2006-12-12T23:43:00.003-08:00

Up to 10 Citizen CNC sliding head automatic lathes with Windows based control system software can now be remotely monitored through unmanned production periods with automatic alarm messaging on alert.

Up to 10 citizen cnc sliding head automatic lathes with Windows based control system software can now be remotely monitored through unmanned production periods with automatic alarm messaging in the event of a problem. Says Geoff Bryant managing director of Citizen's Watford-based UK distributor NC Engineering: 'This system will enable Citizen users, which do not have 24 hour manning of their machine shops, to have the confidence to run around the clock while being able to monitor what is happening in the case of high priority work.' NC Alarm Alert will provide information of the cause of a problem such as coolant low or tool failure through three levels of communications using synthesised speech, mobile phone texting or email alert. These are all configurable by the user to give, for instance, different personnel for each mode of contact and repeat alert at scheduled intervals.

Each machine can also create up to three alert messages in each mode of communication which enables up to nine different people to be contacted.

The system can be configured to limit alerts to certain times of the day, only specified number of alerts from selected machines and options to ignore, for instance, workpiece counter full.

Voice alerts can be acknowledged through the receiving mobile or fixed telephone keypad and shutdown can be achieved by selecting zero.

Sliding head autos move in on body piercing scene

2006-12-12T23:43:00.001-08:00

Body piercing may not be immediately associated with CNC sliding head automatics, but body jewellry and piercing equipment maker has bought six such machines for their high precision.

Grant Dempsey's decision to invest in six citizen cnc sliding headstock lathes and unmanned 'lights-out' production from NC Engineering of Watford, owes as much to the high precision and high quality surface finish he can obtain on very difficult to machine materials at the point of maximum support by the guide bush, as it does to productivity improvements and cost savings. A qualified electrician, Dempsey came to England from Melbourne several years ago and has since turned an abiding interest in body piercing - he is a member and former European secretary of the Association of Professional Piercers - into a thriving business. His Tottenham Hale-based company, Cold Steel International, is the hub of a wholesale operation that has a turnover in the UK alone of over GBP 2 and exports 70 per cent of production.

It was in 1996 that Cold Steel International began supplying everything from body jewellery to piercing equipment, as well as consumables such as sterilisation and after-care products, to distributors around the world.

The company is also a successful retailer with an outlet in London's Camden Town and two further outlets in San Francisco.

'This', says Dempsey, 'is the result of combining my piercing knowledge and experience with an absolute commitment to quality, whether in terms of the jewellery we design or the equipment used to manufacture it.' As business was growing fast all manufacture had been sub-contracted, which meant trusted suppliers were producing more and more of the standard range of jewellery in batches of as many as 50,000 parts.

'This also created problems for us because they were so busy and had no time or capacity to produce or try out new designs which come thick and fast.

For instance, last year some 230 new products were added to the range and our sub-contractors certainly did not relish the idea of loads of small batches of newly designed parts.' So, in late 2002, the decision was made to start manufacture in-house as well as through sub-contract.

This would enable new designs to be brought forward very quickly and under total control.

Given the relatively small sizes of body jewellery such as studs, rings and barbells, the reliance on difficult-to-machine materials such as surgical steel, titanium and niobium, and the overriding requirement for a surface finish free of any blemish that could pose a threat to the wearer's health, the decision to begin in-house manufacture was not taken lightly.

Explains Dempsey: 'It's a challenging combination of precision engineering and finishing to a goldsmith's standard or better.' He then set about researching the market for the most appropriate machines for his type of work.

'We contacted Citizen's UK agent, NC Engineering, emphasising our determination to be up and running as quickly as possible and as it was a new venture we explained we did have some budget constraints.

'NC Engineering resolved the problem by providing machines from its pre-owned stock of two Citizen B12s and larger L20 which gave us the flying start we needed and as they were warranted by NC Engineering, we were confident we could not only catch up with demand but could also begin creating a host of new designs.

Three months later we purchased another pre-owned B12, and as things were progressing so well we then decided that a new L20 and a new M32 were on the cards,' he says.

The top-of-the-range M32 is equipped with two opposed spindles and its multiple tool holding capability of up to 80 tools provides several options for quick setting and simultaneous front and back machining.

It combines the versatility of a machining centre with that of a lathe for complex parts up to 32mm diameter.

'However,' says Dempsey, 'by offering a range of machines from the low cost B-Series through to the sophisticated M-Series, Citizen has a model to suit every requirement and this enables us to benefit from common programming, setting technologies and tooling.' Although impressed with the performance of his Citizen machines, Dempsey has been equally impressed by their reliability.

'Two people set and run the machines during the day and we then run them unmanned through the night,' he says.

'It has been suggested that we are mad to do this given the type materials we work with, but we have never experienced a problem.

I look on unmanned running as a bonus rather than an absolute necessity because for us, quality is the driver.

Every part here is 100 per cent inspected and we now find defective parts are virtually non-existent.

This is crucial because hygiene and health considerations dictate that any returns must be destroyed.' Dempsey describes how a single design can have a lot of variants.

For instance, a barbell destined for an eyebrow piercing is offered in various materials and eight different lengths up to 12mm.

It has a 2mm or 3mm diameter securing which features a M1 or M2 internal thread with undercut.

Also, a matching degree of precision is required for seating semi-precious stones that can be pressure set into the barbell.

Ethnologists point out that body piercing has been a profound part of many cultures for thousands of years and such human needlepoint is now mainstream fashion.

And if anyone could persuade you to give it a try, it is Dempsey who, in his piercing days, had a broad clientele ranging from doctors to nurses, lawyers to policemen, and businessmen to punks.

'People who would not otherwise dream of talking to each other can always be found in our retail stores discussing their body piercings,' he says.

'It really is an across-the-board interest and with some, just like tattooing, it is something of an addiction.

Higher speed processing slices down cycle times

2006-12-11T23:42:00.001-08:00

Latest CNC sliding head mill/turn centre is able to slice its predecessor's cycle times down by over 30% thanks to containing higher speed processing technology and special software macros.

With the launch of the latest Citizen C16-VII CNC sliding head mill/turn centre at MACH 2004, proven cycle times on the previous generation of C16 should now be able to be cut by over 30 per cent when using an existing program. Central to the high output capability of the new machine is its new control system containing higher speed processing technology and special software macros able to reduce by half non-cutting and idle times such as for collet operation and tool positioning times. Faster acceleration and deceleration of all axes significantly quickens machining cycles and a new chute-style parts-catcher is able to operate twice as fast as before.

Examples of the performance enhancement of the new machine are a mild steel dowel 8 mm diameter by 20mm long produced at NC Engineering's Watford showroom with the same NC program from a previous generation machine.

Using two tools to face, chamfer, feed-out and part-off, the time was just 3.5 seconds.

The previous C16 would have taken 10 seconds.

A further trial on a complex brass component, which required 16 operations in a single cycle used to take 30 seconds.

The new machine cycled complete in 19.9 seconds while another 40 second cycle on a brass part using the machines 22 tool positions was cut to a fraction over 30 seconds.

The new C16-VII is also available with an optional 18 mm bar size to compliment the standard 16mm capacity.

It also has four driven tools as standard with an option to specify up to 10.

Able to machine with two, or depending on the specification three tools simultaneously, the new machine provides a significant leap in productivity.

Both main and subspindles can be run at up to 10,000 revs/min and contribute to faster floor to floor times by overlapped cycles.

A 12 position toolpost has six tools facing each spindle while a two-axis yoke-style tool slide is able to mount four 8,000 revs/min rotary tools.

In addition, a perpendicular toolpost holds six turning tools.

Maximum cutting length is 200mm but with the addition of a long workpiece unit, components up to 400mm long can be machined.

Bar automatic deploys three tools simultaneously

2006-12-11T23:42:00.000-08:00

Twin-opposed-spindle bar automatic has a novel turret guideway system that is stiffer and gives additional space in the working area allowing three tools to cut simultaneously.

A new design of twin-opposed-spindle bar automatic has been introduced by the German manufacturer, Index, that distinguishes itself by a novel turret guideway system having a cast iron plate sliding over ceramic-coated steel strips. It is several times stiffer than traditional slideways, has better damping characteristics and is also more compact, giving additional space in the working area. X- and Z-axis drives to the upper and lower turrets are via kinematic rods behind the bed.

Both turrets also have a conventionally driven Y-axis stroke of 70mm.

The machine is available from sole UK agent, Geo Kingsbury, in two sizes designated SpeedLine C42 and C65, the numbers representing the maximum bar capacity in millimetres.

A full C-axis and 20kW/105Nm of spindle power are provided at both ends, delivering top speeds of 6,300 rpm and 5,000 rpm for the respective models.

Clearance between the 140/160mm diameter chucks for between-centres work is 615mm.

The opposed spindle is not only powerful but also has the unusual option of 150mm of X-axis movement in addition to 600mm of longitudinal travel.

By adding the extra degree of freedom in X as well as having the usual Z-axis motion, and electronically coupling them with the X/Z movements of a lower, double-sided, 24-tool turret (optionally available in place of the single-sided version), Index provides the ability to have three tools in cut simultaneously.

This is achieved by having the upper 12-station turret and the left face of the lower turret machining a component in the left hand spindle while the 'slave' right hand spindle follows the latter turret around, enabling a parted-off component to be machined using the right face of the lower turret.

In other words, the X- and Z-axis movements of the lower turret resulting from the cutting cycle in the left hand spindle are continually allowed for in the programmed movements for back-working.

The only limitation when cutting with three tools is that the Y-axis movement of the lower turret cannot be used for front-end machining, as the opposed spindle would be unable to follow.

Idle times are minimised by fast rapid traverse rates in X, Y and Z of 25, 50 and 12m/min respectively.

A steeply angled bed assists swarf removal from the working area of these 6.5 tonne mill-turning centres, whose 5kW/16Nm / 6,000 rpm driven tool capacity is available at all 12 stations of each turret.

Noteworthy too is polygon generation using a head mounted directly on the counter spindle rather than on a turret, ensuring vibration free machining and hence greater accuracy and longer tool life, especially on alloy steels.

CNC sliding head auto mills and deep-hole drills

2006-12-10T23:41:00.000-08:00

As well as milling and drilling, a 32mm capacity CNC sliding head automatic will also perform deep-hole drilling and boring to a 60:1 length:diameter ratio.

As well as milling and drilling, a 32mm capacity CNC sliding head automatic will also perform deep-hole drilling and boring to a 60:1 length:diameter ratio. Adding the cost-effective production of turned and milled features to components up to 32mm diameter, which also have deep hole drilling and boring requirements, will be demonstrated on the latest C32-VIII CNC sliding head automatic lathe from Citizen at MACH 2004. The new machine, now available from NC Engineering of Watford, is able to produce deep holes up to 60:1 length to diameter ratio which equates to a 200mm depth for holes of 3mm diameter.

Power to the 8,000 revs/min main and 7,000 revs/min sub-spindles is high for a sliding head machine at 7.5kW and 3.7kW respectively.

A further advantage of this 32mm capacity machine is its highly flexible tooling arrangement which enables very short cycle times to be achieved and is enhanced with the capability to use up to three tools cutting at the same time.

And with a new control, processor and high speed macro software development, any lost time through axis positioning is minimised while special feature machining such as rigid tapping and threading can be carried out at higher speeds than before.

The C32-VIII has two vertical gang tool posts.

One has five turning tools and four, 1kW, 4,500 revs/min driven tool positions while the second gang tool slide will accommodate four front machining tools in conjunction with the main spindle and has five positions with an option for four 1kW powered rotary tools to perform operations at the secondary spindle.

As an example of its simultaneous machining capability, while the current part is held in the main spindle, the outside diameter can be turned from the gang tool post while it is drilled from the second gang tool slide at the same time as the back tool position of the same slide is used to machine a feature at the secondary spindle.

To maximise the deep hole drilling capability of the machine, program controlled high pressure coolant delivery at up to 2,000lb/in2 ensures optimised tool penetration rates with good surface finish and extended tool life through precise control over any swarf generated by the tooling.

As an option, a 1kW rotary tool drive can be fitted to the second gang tool post which will enable features on the front face of a component, such as pitch hole drilling and slot milling, to be performed in-cycle.

CNC sliding head autos do them in one hit

2006-12-10T23:40:00.000-08:00

Higher performance CNCs offering data processing and software, plus the ability to speed up machining cycles feature six CNC sliding head autos to be spotlighted at the MACH 2004 show.

A major boost to 'one-hit' machining productivity is the theme across six new Citizen mill/turn centres with capacities up to 32mm diameter being demonstrated under power on the NC Engineering stand at MACH 2004. As a result of higher performance CNC controls, data processing and software, an up to 72 tool capacity on one machine and three tool simultaneous cutting enabling cycle times up to 25 per cent quicker to be achieved using the same CNC program as on previous generation machines - there will be a lot to see. For example, the new linear drive Citizen RO4, capable of a massive 40 per cent faster machining cycle than could be achieved with a traditional cam auto producing parts up to 4mm diameter and the new C16 CNC sliding head auto will be demonstrated able to cycle some 30 per cent faster than before.

NC Engineering's Citizen mill/turn centres are clear market leaders in their sector around the world.

This position is maintained through constant attention to market trends, customer needs and machine development, control systems and the cutting process which is qualified with the six new machine introductions.

The new six-axis Citizen RO4 has a 16, 000 revs/min main spindle, 10, 000 revs/min secondary spindle with 13 tools of which two are driven and held on two independent toolposts.

Material capacity is 4 mm with an option of 5.5mm diameter available.

Rapid acceleration through the linear drives to 30m/min traverse rates means cycle times have minimum lost time and accuracy is high with increments of 0.0001mm in each axis to maintain a repeatability of one micron.

The largest mill/turn centre in the Citizen range is the 14-axis Series 3 M32-V which has an additional Y cross-feed axis fitted to the 10 station turret as well as to the gang tool slide which has four driven tools and five turning tools.

A back toolpost has three tool positions.

All three slides are able to machine simultaneously through the new control using high speed macros and faster data processing.

Shown for the first time in the UK is a further 32mm capacity Citizen machine, the C32-VII which has a major advantage in its deep hole drilling and boring capability for holes up to 60:1 ratio of length to diameter.

This equates to 200mm depth for a 3mm hole.

Like the M32, it is capable of three tool simultaneous cutting and has a new high speed processing control.

To aid deep hole work, the Cool Blaster 2,000 lb/in2 high pressure coolant system will be demonstrated which removes many of the problems associated with deep hole drilling such as swarf control; it clears the working area, enables faster penetration rates and extends tool life.

A new version of Citizen's the top international seller, the L-Series shown as an L20-VIII, now has a more rigid frame, which enables 25 per cent more power to be applied to the driven tools.

Tool capacity is increased to 21 tools of which three can be simultaneously engaged on the part.

Now through special adapters, flexibility of setting is improved allowing a three driven tool spindle to be interchanged with front cutting tools by simply turning the unit 90deg.

A cross-spindle can now also be used for turning if required.

Two versions of the new C-Series in 16mm capacity are being demonstrated, the competitively priced entry-level C16-VIE and higher specification C16-VII.

The 17 tool C16-VIE combines a yoke style tooling arrangement around the main spindle which enables short stroke, extremely fast tool positioning.

A gang slide holds six turning tools, three driven tools and a high precision four station toolpost can present up to eight tools allowing machining operations to be carried out at both the main and secondary spindles.

Combined with the new control and software macros, the C16-VIE is faster than the previous entry level sliding head lathe, the highly popular Citizen B-Series.

Meanwhile, the C16-VII, which is now also available in an 18mm capacity variant, will hold 22 tools of which four are driven and there is a further option of having 10 driven tools.

Two or three tool simultaneous machining can be performed and a new control with faster processor transforms the production cycle capability by cutting down idle times.

This equates to a saving up to 20 per cent on an existing proven C16 program.

A major feature of this machine is its excellent access for setting.

As part of NC Engineering's input to production software development in conjunction with Citizen, the Alkartpro off-line programming and cycle optimisation software and the NC Alarm Alert system that enables remote monitoring of up to 10 citizen machines with automatic alarm messaging will be demonstrated.

Sliding head lathes excel in second-operations

2006-12-09T23:17:00.001-08:00

Three sliding head CNC automatics, recently added to a machine inventory of some 100 single- and multi-spindle lathes, have already brought in more new work for the factory owner.

Wilco Manufacturing, Birmingham, specialises in the sub-contract manufacture of precision turned parts. Its policy is to offer customers as diverse a service as possible in three main areas: complexity of component produced, from a simple dowel to a complicated turn-milled part; batch sizes it is prepared to undertake, which currently range from 500- to 500,000-off; and delivery service, either kan-ban, schedule or discrete orders. With further diversification in mind, the company has supplemented its 100 or so single- and multi-spindle cam automatics, sprints and fixed-head CNC lathes with three sliding-headstock, multi-axis turning centres from Star Micronics GB.

In addition to broadening the scope of its manufacture, the other main driving force behind the acquisitions was to eliminate costly secondary operations performed on conventional drilling, milling and capstan machines in order to reduce manufacturing costs, improve product quality and become even more competitive.

So, when evaluating the available sliding-headstock lathes on the market, particular attention was paid to the power and speed of the driven tool stations and of the sub-spindle for reverse end-working.

It was this that led to the selection of Wilcos original Star SR-20RII lathe in October 2003, followed in autumn 2004 by the purchase of two further, identical machines.

Compared with the other short-listed sliding-headstock lathe, the Star offered 25 per cent more power on the five driven cross-working tools, which are rated at 1.2kW, as well as a 60 per cent higher top speed of 8,000 rev/min.

The machine also offered a 1.5kW(cont)/2.2kW(15min) sub-spindle motor, double the power available on the competitors machine.

Consequently the Star lathe is easily capable of drilling and tapping holes up to 8mm diameter/M8 in the back of components.

Another advantage was that the sub-spindle and four powered reverse end-working tools, one more than on the competitors model, could work totally independently of main spindle operations served by the platen.

In all, eight of the 28 cutters in the working area of a standard SR-20RII can be used in combination with the sub-spindle, allowing considerable machining versatility.

Furthermore, in respect of the front end-working tools used with the main spindle, four were provided on the Star machine, one more than on the competitors model, and again these operations may be carried out independently of sub-spindle operations.

All this may seem a little obscure, but as Martin Lane, Managing Director of Wilco points out, such enhancements in machine design translate into shorter cycle times and in some cases the ability to finish-machine a component in one hit instead of having to perform a second operation, resulting in lower manufacturing costs.

Often, Wilco has to centre, drill and tap a hole in the back of a component as well as turn the end face or O/D.

So if only three stations are provided for end-working, one of the operations would have to be carried out using a rear-facing tool mounted on the back of the front end-working attachment or in the cross-working post.

As these are both linked to the turning platen, no simultaneous machining in the main spindle would be possible and productivity could be lost.

An example of where a considerable productivity improvement has been made on the Star machines is in the manufacture of a 5/8in A/F hexagonal steel connector for the automotive industry.

Wilco used to produce it in four successive operations on a single-spindle automatic, a magazine-loaded auto and a drilling machine, followed by manual deburring.

The sum of the previous cycle times was 95 seconds and manual handling was required between the separate operations.

The same component is now machined completely in one automatic cycle, in half the time, on one of the Star lathes and with improved repeatability, 24 hours a day.

Moreover, the absence of inter-operation handling has eliminated potential damage that was previously caused on occasion to the 3/8in UNF male thread at one end, eliminating scrap or rework.

Another example that shows a big improvement is an hydraulic component produced from 0.400in diameter ground mild steel bar.

This part also used to be manufactured in four set-ups: turning, drilling and tapping a 2-56 UNC thread at one end on a single-spindle automatic; reversing the component, forming an end taper and drilling a 4.5 mm diameter blind bore from the other end; milling a 1.5mm deep by 1.5 mm wide slot along the length of the component; and cross-drilling a tiny 0.8 mm diameter hole to meet the initial hole made for the 2-56 UNC tap.

The 93-second total cycle time has been cut by over a third to 58 seconds on a Star lathe and manual handling has once again been eliminated.

Batches of typically 2,000-off are produced and the lead-time has been cut from four weeks to one, dramatically improving customer service and reducing work-in-progress.

Wilco Manufacturing obtained a DTI grant through a Regional Selective Assistance Scheme to help purchase the three Star lathes.

It enabled Lane to telescope a five-year plan to acquire the sliding-headstock lathes into one and a half years.

The original idea was to transfer work requiring multiple operations from the conventional machines to the first Star lathe.

In practice, however, when customers heard that sliding-headstock capacity was available, new business rolled in so quickly that it filled the machines capacity.

Lane confirms that between the first Star machine coming in and the installation of the other two, in excess of GBP 100,000 of new work was won as a direct result of having sliding-headstock turn-milling capability.

Furthermore, the second and third machines are currently sampling new orders from back inquiries and if these also come to fruition, a further GBP 150,000 of business will have been won partially as a consequence of having bought the first Star.

All three machines are fitted with a full length FMB automatic bar magazine and are mainly employed for producing stainless steel, steel and alloy components in cycle times ranging from 18 to 90 seconds to a general tolerance of +/-0.015 mm, which is easily held.

All work going through the machines tends to be high accuracy, complex components that would traditionally require multiple secondary operations, so the powerful cross machining and reverse end-working capabilities of the Stars are nearly always employed to extract maximum benefit from the machines.

Whereas the cam automatics are only operated during the manned day shift, all the bar-fed CNC machines run overnight without operator attendance, contributing significantly to Wilcos productivity.

The company was established in 1940 as a subcontractor serving the automotive industry, principally the Rover Group.

By the mid-1990s, over 90 per cent of the company's turnover was in the automotive sector.

With the BMW takeover, the trend at that time was for component and sub-assembly production to be outsourced to other countries such as Brazil, and for overseas-built engines to be imported rather than made here, all of which reduced the amount of work available to UK subcontractors.

Lane resolved to diversify into a number of other areas including electronics, leisure and hydraulics, the latter now accounting for 15 per cent of the companys GBP 1.4 million turnover, while the proportion of automotive work has dropped to 60 per cent.

The recent entry into sliding-headstock turning will assist the company to spread its work more widely over different industries, further reducing its exposure to the automotive sector.

It will also place Wilco in a better position to compete with the increasing number of low-wage manufacturing nations on the world scene, notably China, India and Eastern European countries.

Photographs herewith, captioned: 1.

The three Star SR-20RII sliding-headstock lathes on the shop floor at Wilco Manufacturing, Birmingham.

2.The machining area an SR-20RII, showing simultaneous front and reverse end-working in progress on a steel hydraulic component, which is now produced complete in 58 seconds.

3.The steel hydraulic component seen from both ends, showing the operations in both faces, the longitudinal groove and the 0.8mm diameter cross-drilled hole, which would be inefficient to machine without 8,000 rev/min live tool stations.

Fire supression is standard on sliding head autos

2006-12-09T23:17:00.000-08:00

As a duty of care to its customers, sliding-headstock lathe company now fits automatic fire suppression systems as standard equipment on all new machines delivered to customers in the UK and Eire.

As a duty of care to its customers, sliding-headstock lathe company, Star Micronics GB, now fits automatic fire suppression systems from Nobel Fire Systems as standard equipment on all new machines delivered to customers in the UK and Eire. The safety equipment can also be retrofitted to lathes already in use. In response to fierce overseas competition, manufacturers and subcontractors are increasingly running machine tools 24/7 and for a large part of that time unattended.

There is always a risk of fire due to the ignition of cutting fluids and certain combustible metals such as titanium and magnesium alloys.

Nobels range of systems has demonstrated 100 per cent success in automatic dousing of fires in machine tools.

The result is minimum downtime before return to full production, as well as possibly saving the machine tool and indeed the whole factory from going up in flames.

Actuation of the fire suppression system is accompanied by automatic machine shutdown, as it is linked into the machines CNC.

Each system will automatically detect a fire and actuate suppression, but should an operator be present, the system can be triggered manually, giving complete control and flexibility.

The fire suppression systems conform to strict standards and depending on the suppression medium chosen, are manufactured to, and meet the requirements of BS5839: EN54; BS5306; NFPA11a; NFPA 750; UL2127.

All are manufactured under ISO 9001/2 and are CE marked.

As a result of the systems conforming to internationally recognised standards, some insurance companies may offer enhanced terms when providing cover for adequately protected machines.

Open house invites in orders

2006-12-08T23:16:00.000-08:00

Star GB received nine orders for sliding-headstock turn-milling machines at its open house exhibition, held from 18th to 22nd October 2004 at the company¹ s Melbourne showroom.

Star GB received nine orders for sliding-headstock turn-milling machines at its open house exhibition, held from 18th to 22nd October 2004 at the company' s Melbourne showroom. Three additional lathes were sold during October, bringing total order intake for the month to over £1.2 million. All were single-machine orders from subcontractors, three of which are new customers to Star and first-time users of sliding-headstock lathes.

Unsurprisingly, therefore, four of the orders were for Star's entry-level, 16 mm bar capacity machine, the SB-16.

At the other end of the scale, among the three 32 mm capacity machines sold was the new SR-32J platen-configured model, on show for the first time in Europe, as well as a top-end capability ECAS-32T turret-type machine.

CNC sliding head auto mills complex 3D forms

2006-12-08T23:15:00.000-08:00

It is the high flexibility generated through the four-axis, 16 tool all-driven turret of a CNC sliding head auto that enables a combination of complex 3D forms to be milled.

It is the high flexibility generated through the four-axis, 16 tool all-driven turret of the latest Maier ML ProLine 32E CNC sliding head auto that enables a combination of complex three-dimensional forms to be milled and, through a fully programmable 0.01deg angle positioning axis, precise in-cycle machining from the turret of angled internal and external features and holes. Now available through StarragHeckert UK of Brackley, the 12-axis Fanuc 160iT CNC, all servo-controlled machine is targeted at more complex part machining requirements such as those found in medical implants, telecomms, hydraulic and fuel injection type applications and often required in difficult to machine high tensile materials. Mounted upon a polymer composite base with the highest levels of thermal stability, rigidity and therefore minimal effects of vibration, three totally independent carriages enable up to three tools to be engaged on a workpiece at the same time.

The construction also supports high feed rates up to 32m/min reached with an acceleration to full speed within 1mm of travel and enables idle times to be minimised thus maintaining full use of the highly flexible tooling arrangement without any loss of productivity.

The sliding head mill/turn centre combines two-axis main and three-axis secondary spindles with an octagonal turret having 16 all-driven positions with tools mounted side by side and positioned via an X-axis cross feed.

Altogether, there are 36 tool positions of which 26 can be driven by 1.5kW motors to provide a wide option of tooling arrangements to satisfy high productive 'one-hit' cycles.

The main and opposed spindles both have C-axis positioning with 5.5kW, 6,000 rev/min drive and a stroke of 220mm for the main Z1 and 230mm of travel for the opposed Z2 spindle.

Surrounding the main spindle is an X-Y tool carrier able to hold four powered cross-machining tools and six turning tools.

The three-axis back working attachment, which has its own Y-axis feed, is able to position three static and six live tools arranged in a grid fashion that maximises setting flexibility and creates short tool movements to engage with the workpiece.

A fully programmable 120 bar high pressure coolant system is optional to the standard system along with quick-change tool holding system.

Specialised cycles such as thread whirling, polygon turning and forming, right angle and adjustable angle drilling/milling units are also available along with part support and separation for machining long components.

Sliding head automatic lathe is fast and flexible

2006-12-07T23:15:00.001-08:00

Citizen's new K-Series CNC sliding head automatic lathe combines two opposed spindles offering up to six turning tools, eight end-working tools and seven driven tools.

Citizen's new generation K-Series CNC sliding head automaticlathe combines two opposed spindles offering up to six turningtools, eight end-working tools and seven driven tools to givehigh precision single-hit cycles for parts up to 12 mm or 16 mmas an option. The stylised machine presents new Citizen livery oftwo shades of silver with a polished stainless highline andlift-up guarding for easy access to the working area. Fastfloor-to-floor cycle times and flexibility of setting were keydesign briefings on the new K-Series represented by the initiallaunch of the K12-VII.

The main spindle has a 3.7 kW drive, some50 per cent more powerful than the previous entry level B-Seriesmachines of Citizen and produces 15,000 revs/min.

The maximumspeed of the sub-spindle is 10,000 revs/min.

The main spindle hasC-axis as standard and the sub-spindle 150 indexing with anoption of full C-axis.

A massive 200 mm of headstock stroke isachieved through a synchronised motor driven guide bush.Unusually for this type of machine, the tool shank is 12 mm toenable heavier, faster cutting cycles from the higher rigiditymachine.

There is also an option for 10 mm shank tooling.

Thesesquare shank tools are mounted on the highly efficient yoke-styletool carrier set around, and close to the spindle, whichminimises tool travel.

And, even with the short distance betweentool and workpiece, the rapid travel rate is 32m/min, some 50%higher than the previous B-Series machine range.

Central tosimplicity of programming but also for ultra-fast dataprocessing, the Citizen K12 uses a special version of the latestFanuc 31i Series control system with newly developed processors.Citizen's own software minimises idle time, makes most ofthe high acceleration available for axis movements andcapitalises on the capability for optimising the cutting process.The machine is compact requiring a floor area of just 930 mm by1680 mm.

Lathes allow round-the-clock manufacture

2006-12-07T23:14:00.000-08:00

Norfolk-based Mussett Engineering is using two DECO 20a automatic sliding head CNC lathes from Tornos to manufacture parts round-the-clock for a leading producer of writing implements.

Norfolk-based Mussett Engineering is using two DECO 20a automatic sliding head CNC lathes from Tornos to manufacture parts round-the-clock for a leading producer of writing implements. Mussett Engineering, located 10 miles southeast of Norwich, claims to be the largest sub-contract engineering facility in the East of England: boasting a workforce of over 100 and an array of some 50 CNC machine tools at its 33,000 sq ft facility, the ISO9001:2000 accredited company is probably right. Although in recent years the company has tended to specialise in the manufacture of complex parts in batches of 10-100 for the aerospace, automotive, oil, petrochemical and compressor sectors, some contracts still call for batches of up to 20,000 components.

For this reason Mussett Engineering can keep its two 10-axis DECO 20a sliding head autos busy 24 hours a day.

'We originally acquired the machines to tackle a very small diameter part for the telecommunications industry,' says managing director and founder, Gordon Mussett.

'However, they are so versatile that we have since used the machines to produce parts for a number of different sectors, including medical and armaments.

At present they are both running non-stop producing internal and external components for writing implements.' Mr Mussett says that the Tornos machines have helped cut cycle times dramatically in comparison to the company's conventional twin turret, twin head machines.

'I recall one part, a regulator for a pressure gauge valve, which previously took 6 minutes 35 seconds on a twin turret, twin head lathe that was subsequently reduced to 1 minute 45 seconds on a DECO 20a,' he confirms.

'There are many more examples where cycle times have been at least halved, with many operations reduced to just one.' Yet despite the significant reductions in cycle time and number of operations, Mussett Engineering witnesses no compromise in quality from its Tornos machines.

'The quality of the machines and the quality of the products they produce were primary reasons behind our decision to buy Tornos,' explains Mr Mussett.

'If we get our bar preparation right, these machines have no problem holding micron tolerances time-after-time.' A three-shift system allows Mussett Engineering to run 24 hours a day for nearly seven days.

Using only one operator to oversee both Tornos machines permits the company to price its products extremely competitively in what has become a tough marketplace.

Yet such is the economy of the machines that Mr Mussett says he doesn't always need large volumes to bolster the bottom line.

'We've put batches as small as 200 on the Tornos machines,' he says.

'For long, slender shaft work there isn't much that can beat these machines, even for low volumes.' Such is the success of the current contract for writing implement components that both Tornos machines are fully loaded for the foreseeable future.

'It's true that we haven't got much capacity to sell on these machines at present,' says Mr Mussett.

'The only way we can fit other jobs in is to get ahead and make a gap in the schedule, but that's not a bad situation to be in is it?' he says light heartedly.

The pattern of growth at Mussett Engineering shows no signs of abating.

In fact, it is only the local shortage of skilled labour that is holding the company back.

Such is the extent of the problem that Mr Mussett has resorted to advertising as far afield as the Midlands in an attempt to attract skilled people to relocate.

'If we could find 25 skilled people tomorrow, we could find jobs for them,' he says.

'We will expand only as fast as we can find the right personnel.

However, we do not let our customers down.

We offer realistic delivery times and stick to them.

For this reason we have probably turned down as much work as we have taken on lately.

It is easy to say 'yes' when new work presents itself but I don't believe in making promises that will be tough to keep.' With a bulging order book Mussett Engineering has to get maximum output from all of its machine tools and the DECO models are no exception.

'Thankfully the reliability of the Tornos machines has been exceptional,' concludes Mr Mussett, 'which is a relief because we cannot afford to have a single moment of downtime at present.