New from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system.
Extending its highly competitive and cost-effective 'Lights-out' machine package strategy for the top-selling Tornado range of CNC turning centres, new from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system. Available from Colchestersales of Heckmondwike, the Tornado T6MS is a true integrated mill/turning cell devised for maximum utilisation involving unmanned operation. Now with loading and unloading of components performed by purpose developed automation, that operates within the confines of the machine without additional guarding or fencing, it sets a new standard for economic production at, in true Colchester Lathe tradition, an affordable price.
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 with automatic part transfer between main and subspindle for parts up to 80 mm diameter by 100 mm long and weighing up to 5 kg.
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 of either part stockers, carousel, palletising or conveyor systems.
The different types of material and work handling systems are able to manipulate raw material supply to the main spindle and accept the off-load of completed parts from the main or subspindle enabling the production cycle to continue independent of the loading system.
The loading system therefore is able to carry on to complete the handling sequence with the part storage elements and is able to be parked clear of the machine working area to enable normal machine operation.
The Tornado T6MS has a 440 m swing over bed and 220 mm maximum turned diameter by 450 mm long with a 54 mm bar capacity and 130 mm chuck size.
The 15 kW, 6,000 revs/min main and 5.5 kW, 6,000 revs/min subspindle are serviced by a 12 station all-driven tool turret with 3.7 kW, 5,000 revs/min drive.
Rapid traverse rates are 30 m/min in Z and 25 m/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 with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.
Saturday, May 27, 2006
CNC lathes chosen for college facility
Some GBP 3 million has already been allocated to a College's Technology Suite, for which the CNC lathe installations have been a focal point of a GBP 700,000 investment in new equipment.
The reason East Tyrone College of Further and Higher Education elected to spend GBP 140,000 with Ireland's Colchester Lathe sole dealership, Gillen Machine Tools, was it needed machines installed that would be recognised and accepted by local industry as being the standard of equipment that would provide trainees and engineering students with the experience and knowledge that would be useful in their future careers. As Alastair Booth, lecturer in engineering pointed out: 'With the equipment we have credibility as a top training establishment and are able to perform a positive service to industry in the area and also increase our revenue generation.' East Tyrone College of Further and High Education is based in Dungannon to service Northern Ireland and the border area and has been funded to the tune of almost GBP 20 million for new buildings and facilities. Some GBP 3 million has already been allocated to the Technology Suite for which the Colchester Lathe installations have been a focal point of the GBP 700,000 investment in new equipment.
As a result of 10 years in concept, six years planning and the last three years spent on detail, the Technology Suite will encompass a very modern machine shop, welding and fabrication facility, rapid prototyping, advanced CADCAM and a structural testing and diagnostics suite.
There are also courses available on subject areas such as programmable logic control, customised for local industry and during 2006, a new home automation course is being planned.
The college is the first centre in Ireland to gain certification as an EIB/KNX centre for advanced training in the configuration of bus devices in lighting, blinds control, safety and security and energy cost reduction, The first course is scheduled for February in a new course delivery suite.
Enrolling almost 15,000 students a year, it employs 75 full-time staff and 100 part-time people.
There are also 25 'out centres' and mobile IT vehicles kitted out with 16 laptops that provide Information Technology classes in the community.
The Colchester Lathe contract was clinched following a visit to an Open House set up by Gillen Machine Tools in its showroom at Ballymena when Alastair Booth and his team took the opportunity to see the Colchester machines in action.
In particular they wanted to bridge the manual to CNC technology gap and while they decided that five Colchester Student 2500 conventional lathes fitted with Heidenhain digital readouts gave the perfect training platform/machine combination, providing 'real' turning experience at a very competitive price, it was the Colchester Combi K2 lathe that came across as the ideal solution for what they were seeking in higher technology machining.
Says Alastair Booth: 'It is the versatility of the machine and the Fanuc 21 Oi TA multi-functional control with the user friendliness of Microsoft Windows that provides the ideal bridge we were seeking.
The machine has six ways in which you can input instructions which covers a wide range of programming avenues.' With the Combi, the operator can manually turn a part using the electronic handwheels, and use the control simply as a digital readout for positioning.
He also has the facility to create his own canned cycles as well as using the Colchester developed cycles in the memory or cut and paste to make up toolpaths.
Setting is helped by access to the extensive tool library which can hold up to 960 tools.
There is also the simple teach/repeat memory and on-screen CADCAM, with icon-based commands and, for the more advanced user, conventional CNC programming can be performed using G-Codes.
Programs can also be downloaded by DNC or input from a 'flash card' taken from a PC.
To which Booth adds: 'We also have a full CNC machine in the Combi K2 for repeat cycles that will have the respect of any engineering manager for the way it will perform in production.' Indeed, the College already has the support of 10 local companies taking up a 10 week introductory course to provide a sound understanding of CNC machining techniques and a course for manual machinists to upgrade to CNC.
According to Maria Hackett, head of school and job skills co-ordinator: 'The Dungannon area is the most active in Northern Ireland for engineering and in particular fabrication.
However, there is an increasing number of businesses that want to break into, or upgrade from manual to CNC machining and that is a prime area for us to satisfy with the new equipment.
With the addition of part time staff we will then introduce customised courses for local industry.' Modern apprenticeship courses are also being run on a day-release basis as well as full time BTEC National Diploma in Engineering.
And indeed, keen to catch the prospective student and with a view to nurturing an interest in engineering, the College has structured a series of two-day courses for local school children in conjunction with local businesses to give them an introduction to what engineering is all about.
As part of the two-day course, the children will be involved in projects such as making a CD holder and even be taken to a local engineering company to see real 'live' manufacturing.
Meanwhile, through the Women in Engineering WISE programme, European funding was gained by the College to train 20 women to NVQ Level 2 followed by placement with local employers.
With fresh ideas and schemes like these, Booth is adamant that selecting the right equipment was so crucial.
But as he maintains: 'We will need help with training and retraining as well as technical assistance, and part of our decision to buy the Colchester machines from Gillen Machine Tools is that we will be able to draw heavily on support in times of need.'
The reason East Tyrone College of Further and Higher Education elected to spend GBP 140,000 with Ireland's Colchester Lathe sole dealership, Gillen Machine Tools, was it needed machines installed that would be recognised and accepted by local industry as being the standard of equipment that would provide trainees and engineering students with the experience and knowledge that would be useful in their future careers. As Alastair Booth, lecturer in engineering pointed out: 'With the equipment we have credibility as a top training establishment and are able to perform a positive service to industry in the area and also increase our revenue generation.' East Tyrone College of Further and High Education is based in Dungannon to service Northern Ireland and the border area and has been funded to the tune of almost GBP 20 million for new buildings and facilities. Some GBP 3 million has already been allocated to the Technology Suite for which the Colchester Lathe installations have been a focal point of the GBP 700,000 investment in new equipment.
As a result of 10 years in concept, six years planning and the last three years spent on detail, the Technology Suite will encompass a very modern machine shop, welding and fabrication facility, rapid prototyping, advanced CADCAM and a structural testing and diagnostics suite.
There are also courses available on subject areas such as programmable logic control, customised for local industry and during 2006, a new home automation course is being planned.
The college is the first centre in Ireland to gain certification as an EIB/KNX centre for advanced training in the configuration of bus devices in lighting, blinds control, safety and security and energy cost reduction, The first course is scheduled for February in a new course delivery suite.
Enrolling almost 15,000 students a year, it employs 75 full-time staff and 100 part-time people.
There are also 25 'out centres' and mobile IT vehicles kitted out with 16 laptops that provide Information Technology classes in the community.
The Colchester Lathe contract was clinched following a visit to an Open House set up by Gillen Machine Tools in its showroom at Ballymena when Alastair Booth and his team took the opportunity to see the Colchester machines in action.
In particular they wanted to bridge the manual to CNC technology gap and while they decided that five Colchester Student 2500 conventional lathes fitted with Heidenhain digital readouts gave the perfect training platform/machine combination, providing 'real' turning experience at a very competitive price, it was the Colchester Combi K2 lathe that came across as the ideal solution for what they were seeking in higher technology machining.
Says Alastair Booth: 'It is the versatility of the machine and the Fanuc 21 Oi TA multi-functional control with the user friendliness of Microsoft Windows that provides the ideal bridge we were seeking.
The machine has six ways in which you can input instructions which covers a wide range of programming avenues.' With the Combi, the operator can manually turn a part using the electronic handwheels, and use the control simply as a digital readout for positioning.
He also has the facility to create his own canned cycles as well as using the Colchester developed cycles in the memory or cut and paste to make up toolpaths.
Setting is helped by access to the extensive tool library which can hold up to 960 tools.
There is also the simple teach/repeat memory and on-screen CADCAM, with icon-based commands and, for the more advanced user, conventional CNC programming can be performed using G-Codes.
Programs can also be downloaded by DNC or input from a 'flash card' taken from a PC.
To which Booth adds: 'We also have a full CNC machine in the Combi K2 for repeat cycles that will have the respect of any engineering manager for the way it will perform in production.' Indeed, the College already has the support of 10 local companies taking up a 10 week introductory course to provide a sound understanding of CNC machining techniques and a course for manual machinists to upgrade to CNC.
According to Maria Hackett, head of school and job skills co-ordinator: 'The Dungannon area is the most active in Northern Ireland for engineering and in particular fabrication.
However, there is an increasing number of businesses that want to break into, or upgrade from manual to CNC machining and that is a prime area for us to satisfy with the new equipment.
With the addition of part time staff we will then introduce customised courses for local industry.' Modern apprenticeship courses are also being run on a day-release basis as well as full time BTEC National Diploma in Engineering.
And indeed, keen to catch the prospective student and with a view to nurturing an interest in engineering, the College has structured a series of two-day courses for local school children in conjunction with local businesses to give them an introduction to what engineering is all about.
As part of the two-day course, the children will be involved in projects such as making a CD holder and even be taken to a local engineering company to see real 'live' manufacturing.
Meanwhile, through the Women in Engineering WISE programme, European funding was gained by the College to train 20 women to NVQ Level 2 followed by placement with local employers.
With fresh ideas and schemes like these, Booth is adamant that selecting the right equipment was so crucial.
But as he maintains: 'We will need help with training and retraining as well as technical assistance, and part of our decision to buy the Colchester machines from Gillen Machine Tools is that we will be able to draw heavily on support in times of need.'
Twin-spindle CNC lathe is attractively priced
Equipped with C- and Y-axis plus 12 driven tools, a twin-spindle CNC slant bed lathe - built to Japanese quality - is being offered in the UK at at Taiwanese machine prices.
With C- and Y-axis plus 12 driven tools, the Taiwan Takisawa EX-910 twin-spindle CNC slant bed lathe available exclusively in the UK from Ward CNC of Sheffield offers an unmatched 'Japanese quality at a Taiwanese price' turning centre package. Having X-, Y-, Z-axis travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B-axis (right-hand spindle), the EX-910 features bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement the machine's maximum turning diameter and length capabilities of 340mm and 660mm. Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.
Driven tool speed is 4,000 rev/min from a 5.5kW motor.
Rapid traverse rates are quoted as 24m/min.
As standard, the heavy-duty cast iron construction is complemented by Fanuc 18i CNC, as well as four-track super rigid precision linear guideways and high-speed servo turret, auto tool setting arm, parts catcher and swarf conveyor.
Bar feed systems and collet chucks can be supplied as options.
With C- and Y-axis plus 12 driven tools, the Taiwan Takisawa EX-910 twin-spindle CNC slant bed lathe available exclusively in the UK from Ward CNC of Sheffield offers an unmatched 'Japanese quality at a Taiwanese price' turning centre package. Having X-, Y-, Z-axis travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B-axis (right-hand spindle), the EX-910 features bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement the machine's maximum turning diameter and length capabilities of 340mm and 660mm. Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.
Driven tool speed is 4,000 rev/min from a 5.5kW motor.
Rapid traverse rates are quoted as 24m/min.
As standard, the heavy-duty cast iron construction is complemented by Fanuc 18i CNC, as well as four-track super rigid precision linear guideways and high-speed servo turret, auto tool setting arm, parts catcher and swarf conveyor.
Bar feed systems and collet chucks can be supplied as options.
Thursday, May 25, 2006
CNC universal lathes' function options extended
High quality CNC universal lathes now have a choice of function expansion options including sub-spindle for two-sided machining, driven tools and Y-axis for eccentric boring and milling.
For metal removal performance, flexibility, speed and precision, the newly expandable DMG CTX-10 universal lathes are now unmatched in their price category. Already established as a range of universal lathes that represent good value for money, the CTX-10 Series is now available with a choice expansion options including sub-spindle for two-sided machining, driven tools and Y-axis for eccentric boring and milling. Not only do these allow the machine to grow to meet changing needs but also to be tailored to accommodate the complete machining of standard-sized parts.
Further options include the integrated spindle motor for fast acceleration and deceleration, digital drives and fast-indexing VDI servo turret - starting at 0.1 sec - with 12 tool stations.
These features enable idle times to be reduced by 25% leading to increased productivity and efficiency.
Customers can also specify a package for bar machining with an enlarged hollow clamping cylinder, steady-rest technology for shaft machining and workpiece pick-up units.
The easy integration of these elements is made possible by the build-quality of the CTX-10 machines and their sophisticated control technology.
All models have a 45 deg cast iron bed based on a rigid four-track design with linear roller guideways.
This combination provides the best operating conditions both the dynamic cross-slide and the hydraulically traversable tailstock.
Despite exceptionally quick positioning times, high rapid traverse speeds and dynamic digital drives the CTX-10 models can maintain the highest degree of accuracy thanks to direct measuring systems in the X and Z axes.
This eliminates the need for the time-consuming reference-point method.
For greater operator comfort customers can now also opt for the pivoting DMG SlimLinePanel with 15in TFT screen.
There are also three CNC control alternatives, the Siemens 840D with the latest ShopTurn 3D programming software, Heidenhain Plus IT with DINPlus (optionally TurnPlus), or the Fanuc 32i with Manual Guide i.
For metal removal performance, flexibility, speed and precision, the newly expandable DMG CTX-10 universal lathes are now unmatched in their price category. Already established as a range of universal lathes that represent good value for money, the CTX-10 Series is now available with a choice expansion options including sub-spindle for two-sided machining, driven tools and Y-axis for eccentric boring and milling. Not only do these allow the machine to grow to meet changing needs but also to be tailored to accommodate the complete machining of standard-sized parts.
Further options include the integrated spindle motor for fast acceleration and deceleration, digital drives and fast-indexing VDI servo turret - starting at 0.1 sec - with 12 tool stations.
These features enable idle times to be reduced by 25% leading to increased productivity and efficiency.
Customers can also specify a package for bar machining with an enlarged hollow clamping cylinder, steady-rest technology for shaft machining and workpiece pick-up units.
The easy integration of these elements is made possible by the build-quality of the CTX-10 machines and their sophisticated control technology.
All models have a 45 deg cast iron bed based on a rigid four-track design with linear roller guideways.
This combination provides the best operating conditions both the dynamic cross-slide and the hydraulically traversable tailstock.
Despite exceptionally quick positioning times, high rapid traverse speeds and dynamic digital drives the CTX-10 models can maintain the highest degree of accuracy thanks to direct measuring systems in the X and Z axes.
This eliminates the need for the time-consuming reference-point method.
For greater operator comfort customers can now also opt for the pivoting DMG SlimLinePanel with 15in TFT screen.
There are also three CNC control alternatives, the Siemens 840D with the latest ShopTurn 3D programming software, Heidenhain Plus IT with DINPlus (optionally TurnPlus), or the Fanuc 32i with Manual Guide i.
Long bed CNC lathe offers heavy duty turning
Heavy duty, long bed universal CNC lathe offers users an exceptional combination of turning capacity and capability at an unrivalled cost.
The Taiwan Takisawa EX-122 heavy-duty, long bed universal CNC lathe available from Ward CNC of Sheffield offers users an exceptional combination of turning capacity and capability at an unrivalled cost. With maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min, the machine's cast iron slant bed construction combines with extra heavy duty linear guideway technology to provide an exceptional performance 'Japanese quality at Taiwanese prices' package. Part of Ward CNC's Taiwan Takisawa portfolio, the EX-122 has a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330mm and 1650mm, respectively, and a 200mm spindle bore.
Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.
Auto tool setting arm, bar feed interface and swarf conveyor are supplied as standard; bar feed systems and steady rests are optional extras.
The Taiwan Takisawa EX-122 heavy-duty, long bed universal CNC lathe available from Ward CNC of Sheffield offers users an exceptional combination of turning capacity and capability at an unrivalled cost. With maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min, the machine's cast iron slant bed construction combines with extra heavy duty linear guideway technology to provide an exceptional performance 'Japanese quality at Taiwanese prices' package. Part of Ward CNC's Taiwan Takisawa portfolio, the EX-122 has a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330mm and 1650mm, respectively, and a 200mm spindle bore.
Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.
Auto tool setting arm, bar feed interface and swarf conveyor are supplied as standard; bar feed systems and steady rests are optional extras.
Sunday, May 21, 2006
Subcontractor adds CNC turning to up capacity
When a Welsh subcontract machining company wants to extend capacity, it invests in the latest CNC turning centres, lathes and feeding equipment rather than expand working hours or add shifts.
As the third generation managing director of family-owned TS Henderson located at the foot of the Brecon Beacons, UK, Rob Henderson maintains: 'Most people arrive here thinking they will find a field of sheep, a cow shed and tractors, and they are actually quite surprised - and naturally relieved - when they see our 15,000ft2 factory, our portfolio of over 20 high-tech CNC machines and, in particular, how we utilise our nine Colchester CNC Tornado two- and three-axis turning machines.' Henderson never fails to be amused by the expectations of potential customers when they arrive at the Hay on Wye (Herefordshire) based specialist supplier of high-quality sub-contract parts to, for example, companies in the automotive, electronics, lifting gear, marine and motor sport sectors. While all these customers are based in the UK, he suggests that 80% of the parts he supplies are eventually destined for export. Henderson is very serious when it comes to making the most of his high-tech CNC machining technology to satisfy customer demands for a wide variety of prismatic and shaft-type components in varying batch quantities.
Most of the company's turning work is produced on the Tornado machines - a mixture of two- and three-axis Tornado 80, 90, 220M and the latest T6M models that have been installed progressively since 1996.
All equipped with bar feeders for unmanned, automatic running, the Tornados have consistently proved to be reliable generating high returns on their investment in the production of all manner of parts in all materials - including the often problematic 316 stainless steel - an important factor in his continual investment in the marque against the demands of his order book.
He says: 'In addition to offering the right specification at the right price, the Tornado machines bought from Colchestersales have always been supported with excellent back-up.
This is crucial to us.
And if we do have a problem, with either the machine or programming, for example, we can get superb 'phone support - which means they're not automatically sending out an engineer followed by an invoice.
Customer service on this level means a lot to me, and it gives me great confidence when I need to invest,' he insists.
Henderson's capital expenditure philosophy is equally as pragmatic: to meet any sustained hike in demand, he simply buys additional machines rather than extend the working hours; even though the company's single day shift for 5.1/2 days a week is complemented by the extended running capabilities of the Tornados via bar feed systems.
Currently employing 28 people he outlines: 'If we added another shift, i e, a night shift, we would effectively have to almost double the workforce but you have to be mindful of the effect of a quiet period which could lead to having to lay people off.
For us, installing another machine is a much simpler solution.
Machines do not go to the dentist, they do not have personal problems, and if the workload does dip, then they can be switched off.' Thankfully, he reflects, it has been some time since any machine has stood dormant through lack of work and, in fact, increasing demand - especially for turn/milled parts - during the past two years has spurred the BS EN ISO 9002-accredited company to invest in three-axis driven tool turning cycles from Colchestersales.
It has installed both the Tornado 220M and latest T6M models during 2005 to complement the six Tornado 80 models and a single Tornado 90 two-axis machine.
These machines complement six machining centres and an impressive multi-spindle turning, milling, grinding, thread rolling and centreless grinding capacity.
Specifically designed to combine previous separate operations into a single cycle, TS Henderson has found increased productivity has been achieved at an unrivalled cost-to-performance ratio.
The latest Tornado T6M has a 54mm bar capacity, offers a swing over the bed of 440mm and maximum turning diameters and lengths of 200mm and 450mm, respectively.
With a 15kW spindle motor providing spindle speeds of 6,000 rev/min, coupled with rapid traverse rates of 25m/min and 30m/min in the X and Z axes, for the 12 driven tool VDI 30 turret, the machine has satisfied every demand that Henderson has so far presented it with.
Workpieces successfully machined in a single cycle sequence of turning and milling extend from the complex to the fairly simple, including filter adaptors for the automotive sector and even single parts for steam engines.
In addition to highlighting the machine's impressive build qualities as enabling consistent performance, the Duo-stable construction that uses an inert concrete composite encapsulated in a heavy-duty fabrication and reinforced with a network of ribs for excellent thermal and dynamic stability - Rob Henderson also points to the T6M's Fanuc 21i control system as being particularly beneficial.
The CNC includes the Colchestersales-developed Manual Guide - i conversational programming technology.
This has high level graphics support giving full simulation and verification of any cutting cycle in both 2-D and 3-D plus the ability to manipulate machining operations so that the part and toolpaths can be viewed from any angle.
Not only does this system interface with all major CAD/CAM systems but it also makes programming of single part cycles extremely effective, quick and simple.
Equal praise is also bestowed upon the accompanying ColCAM off-line programming software: 'Once a job is programmed, the cycles are easy to follow with 3D graphics showing the tool tip shape, and axial and radial drilling and milling tool paths clearly depicted,' he says.
Commenting on the effectiveness of 'upgrading' to three-axis machining, Henderson does not mince his words: 'I cannot say that we always achieve fantastic reductions in cycle times on multi-operation work through one-hit machining,' he comments.
'But the real benefit is the reduction in the number of operations, setting and inspection which reflects on reduced lead times and the associated labour resource of transferring parts to, say, a machining centre or pillar drill.' This down-to-earth business philosophy is applied to every aspect of the company - for example, almost GBP 100,000 of round steel/stainless bar, as well as brass, bronze, aluminium and Nylon, is maintained as a key factor to provide immediate response to all customer demands, to complement the usual just-in-time delivery schedules.
And in terms of customer service, it has not been unknown for the TS Henderson delivery van to be despatched to a distant customer with just a handful of parts on board, to meet a particular request.
'Sub-contractors are service providers,' Henderson concludes, 'You need the right equipment to perform the task which we have managed to achieve but if you don't provide a service you will not stay in business.
As the third generation managing director of family-owned TS Henderson located at the foot of the Brecon Beacons, UK, Rob Henderson maintains: 'Most people arrive here thinking they will find a field of sheep, a cow shed and tractors, and they are actually quite surprised - and naturally relieved - when they see our 15,000ft2 factory, our portfolio of over 20 high-tech CNC machines and, in particular, how we utilise our nine Colchester CNC Tornado two- and three-axis turning machines.' Henderson never fails to be amused by the expectations of potential customers when they arrive at the Hay on Wye (Herefordshire) based specialist supplier of high-quality sub-contract parts to, for example, companies in the automotive, electronics, lifting gear, marine and motor sport sectors. While all these customers are based in the UK, he suggests that 80% of the parts he supplies are eventually destined for export. Henderson is very serious when it comes to making the most of his high-tech CNC machining technology to satisfy customer demands for a wide variety of prismatic and shaft-type components in varying batch quantities.
Most of the company's turning work is produced on the Tornado machines - a mixture of two- and three-axis Tornado 80, 90, 220M and the latest T6M models that have been installed progressively since 1996.
All equipped with bar feeders for unmanned, automatic running, the Tornados have consistently proved to be reliable generating high returns on their investment in the production of all manner of parts in all materials - including the often problematic 316 stainless steel - an important factor in his continual investment in the marque against the demands of his order book.
He says: 'In addition to offering the right specification at the right price, the Tornado machines bought from Colchestersales have always been supported with excellent back-up.
This is crucial to us.
And if we do have a problem, with either the machine or programming, for example, we can get superb 'phone support - which means they're not automatically sending out an engineer followed by an invoice.
Customer service on this level means a lot to me, and it gives me great confidence when I need to invest,' he insists.
Henderson's capital expenditure philosophy is equally as pragmatic: to meet any sustained hike in demand, he simply buys additional machines rather than extend the working hours; even though the company's single day shift for 5.1/2 days a week is complemented by the extended running capabilities of the Tornados via bar feed systems.
Currently employing 28 people he outlines: 'If we added another shift, i e, a night shift, we would effectively have to almost double the workforce but you have to be mindful of the effect of a quiet period which could lead to having to lay people off.
For us, installing another machine is a much simpler solution.
Machines do not go to the dentist, they do not have personal problems, and if the workload does dip, then they can be switched off.' Thankfully, he reflects, it has been some time since any machine has stood dormant through lack of work and, in fact, increasing demand - especially for turn/milled parts - during the past two years has spurred the BS EN ISO 9002-accredited company to invest in three-axis driven tool turning cycles from Colchestersales.
It has installed both the Tornado 220M and latest T6M models during 2005 to complement the six Tornado 80 models and a single Tornado 90 two-axis machine.
These machines complement six machining centres and an impressive multi-spindle turning, milling, grinding, thread rolling and centreless grinding capacity.
Specifically designed to combine previous separate operations into a single cycle, TS Henderson has found increased productivity has been achieved at an unrivalled cost-to-performance ratio.
The latest Tornado T6M has a 54mm bar capacity, offers a swing over the bed of 440mm and maximum turning diameters and lengths of 200mm and 450mm, respectively.
With a 15kW spindle motor providing spindle speeds of 6,000 rev/min, coupled with rapid traverse rates of 25m/min and 30m/min in the X and Z axes, for the 12 driven tool VDI 30 turret, the machine has satisfied every demand that Henderson has so far presented it with.
Workpieces successfully machined in a single cycle sequence of turning and milling extend from the complex to the fairly simple, including filter adaptors for the automotive sector and even single parts for steam engines.
In addition to highlighting the machine's impressive build qualities as enabling consistent performance, the Duo-stable construction that uses an inert concrete composite encapsulated in a heavy-duty fabrication and reinforced with a network of ribs for excellent thermal and dynamic stability - Rob Henderson also points to the T6M's Fanuc 21i control system as being particularly beneficial.
The CNC includes the Colchestersales-developed Manual Guide - i conversational programming technology.
This has high level graphics support giving full simulation and verification of any cutting cycle in both 2-D and 3-D plus the ability to manipulate machining operations so that the part and toolpaths can be viewed from any angle.
Not only does this system interface with all major CAD/CAM systems but it also makes programming of single part cycles extremely effective, quick and simple.
Equal praise is also bestowed upon the accompanying ColCAM off-line programming software: 'Once a job is programmed, the cycles are easy to follow with 3D graphics showing the tool tip shape, and axial and radial drilling and milling tool paths clearly depicted,' he says.
Commenting on the effectiveness of 'upgrading' to three-axis machining, Henderson does not mince his words: 'I cannot say that we always achieve fantastic reductions in cycle times on multi-operation work through one-hit machining,' he comments.
'But the real benefit is the reduction in the number of operations, setting and inspection which reflects on reduced lead times and the associated labour resource of transferring parts to, say, a machining centre or pillar drill.' This down-to-earth business philosophy is applied to every aspect of the company - for example, almost GBP 100,000 of round steel/stainless bar, as well as brass, bronze, aluminium and Nylon, is maintained as a key factor to provide immediate response to all customer demands, to complement the usual just-in-time delivery schedules.
And in terms of customer service, it has not been unknown for the TS Henderson delivery van to be despatched to a distant customer with just a handful of parts on board, to meet a particular request.
'Sub-contractors are service providers,' Henderson concludes, 'You need the right equipment to perform the task which we have managed to achieve but if you don't provide a service you will not stay in business.
CNC shaft lathe reduces loading and set-up time
Purpose-built for automated, high-precision, internal and external machining of large shafts and pipes, CNC shaft lathes has automatic chucking and steadying, for rapid loading and set-up.
Classic lathe maker Dean, Smith and Grace of Keighley, West Yorkshire, UK, has received the first order for one of its new breed of CNC shaft lathes - purpose-built for fully automated, high-precision, internal and external machining of large shafts and pipes. Designated 'SE' (Special Equipment), the first in the range, set to be delivered in February to a Northeast UK-based manufacturer of mechanical excavator rams, is a 2817 x 150 model. It incorporates a 4000mm length bed, Fanuc 18i control - and fully automated chucking and steadying equipment, for rapid loading and set-up.
By fully automating the set-up process, large and unwieldy pipes or shafts can be quickly loaded and set-up with just one operator, at a stroke slashing floor-to-floor times for what has historically been a difficult and labour-intensive task.
Providing the quick loading and set-up is a fully automatic SMW KCNS 400 hydraulic, quick release, chucking system; complemented by an SMW type SLU-Z-4 three-point roller steady with mechanical positioning.
The three-point roller steady can traverse the full length of the bed - under operator's control or automatically - to find the optimum position of support, while hydraulically operated jaws clamp to the workpiece or retract as required.
The chuck and steady work in conjunction with an automatic tailstock, designed and manufactured 'in-house' by Dean, Smith and Grace.
The tailstock utilises hydraulic power and the lathe's rack and pinion drive to automatically position at pre-set locations programmed by the operator.
Other features of the 'SE' include: Sauter 12-station auto indexing VDI turret, slat-type swarf conveyor, Fanuc digital motors, precision ball screws and Vogel/Sterling automatic lubrication system - though customers can specify the control/equipment of their choice.
Dean, Smith and Grace managing director, Nigel Grainger, comments: 'Few lathe manufacturers in the world - if any - have a machine range on the market that addresses the 'pipe' lathe sector as comprehensively as our new 'SE' range.
By keeping costs down, building on a proven build spec, and addressing the requirements of rapid loading and set-up using a single operator, this new lathe offers up new standards of cost efficiency and productivity for a wide range of industries.' A significant feature of all Dean, Smith and Grace production, including the new 'SE', is the capability not only to supply 'off-the-peg' lathes, hand-built to the highest specifications, but also individual engineered solutions tailored to the customer's needs.
Thus, Dean, Smith and Grace engineers and designers are more than happy to discuss application requirements before the build phase begins.
Classic lathe maker Dean, Smith and Grace of Keighley, West Yorkshire, UK, has received the first order for one of its new breed of CNC shaft lathes - purpose-built for fully automated, high-precision, internal and external machining of large shafts and pipes. Designated 'SE' (Special Equipment), the first in the range, set to be delivered in February to a Northeast UK-based manufacturer of mechanical excavator rams, is a 2817 x 150 model. It incorporates a 4000mm length bed, Fanuc 18i control - and fully automated chucking and steadying equipment, for rapid loading and set-up.
By fully automating the set-up process, large and unwieldy pipes or shafts can be quickly loaded and set-up with just one operator, at a stroke slashing floor-to-floor times for what has historically been a difficult and labour-intensive task.
Providing the quick loading and set-up is a fully automatic SMW KCNS 400 hydraulic, quick release, chucking system; complemented by an SMW type SLU-Z-4 three-point roller steady with mechanical positioning.
The three-point roller steady can traverse the full length of the bed - under operator's control or automatically - to find the optimum position of support, while hydraulically operated jaws clamp to the workpiece or retract as required.
The chuck and steady work in conjunction with an automatic tailstock, designed and manufactured 'in-house' by Dean, Smith and Grace.
The tailstock utilises hydraulic power and the lathe's rack and pinion drive to automatically position at pre-set locations programmed by the operator.
Other features of the 'SE' include: Sauter 12-station auto indexing VDI turret, slat-type swarf conveyor, Fanuc digital motors, precision ball screws and Vogel/Sterling automatic lubrication system - though customers can specify the control/equipment of their choice.
Dean, Smith and Grace managing director, Nigel Grainger, comments: 'Few lathe manufacturers in the world - if any - have a machine range on the market that addresses the 'pipe' lathe sector as comprehensively as our new 'SE' range.
By keeping costs down, building on a proven build spec, and addressing the requirements of rapid loading and set-up using a single operator, this new lathe offers up new standards of cost efficiency and productivity for a wide range of industries.' A significant feature of all Dean, Smith and Grace production, including the new 'SE', is the capability not only to supply 'off-the-peg' lathes, hand-built to the highest specifications, but also individual engineered solutions tailored to the customer's needs.
Thus, Dean, Smith and Grace engineers and designers are more than happy to discuss application requirements before the build phase begins.
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