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

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

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

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

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

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

This also means an extension of the performance parameters.

Another unique feature is the new vertical tool carrier.

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

There are two tool holders on each side.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

This monitoring is integrated into the control system.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Batch sizes of 20 to 100 are ideal.

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

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

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

Tool changes are carried out concurrent with the cycle time.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

To increase track pitch, the guideways are arranged diagonally.

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

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

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

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

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

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

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

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

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

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

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

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

Sensitive components are located in contamination-free areas.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Today the company employs 200 people at its Kegworth facility.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Bar capacity is 54mm diameter.

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

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

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.

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.

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.

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 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.

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.'

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.

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.

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 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.'

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.