While the focus of attention in British manufacturing continues to be the loss of work to off-shore locations, particularly the Far East, 600 Group remains committed to manufacturing in the UK. The Group is presently half way through a multi-million pound investment programme in its manufacturing plants designed to ensure that each is able to remain at the forefront of its market with competitively priced, high technology products. Recent investment has been concentrated at three of the Group's six UK manufacturing plants, Gamet Bearings in Colchester, Crawford Collets and Pratt Burnerd International in Halifax, and Colchester and Harrison Lathes in Heckmondwike (near Leeds).
Group Chief Executive Dr Tony Sweeten said 'We are a British company.
We are committed to British engineering and to manufacturing in Britain.
The Group has always been part of the manufacturing industry and has grown within it, root and branch.
We survive and thrive because both the Group and the individual companies within it have a commitment to remaining at the forefront of industry by constantly seeking to improve and enhance our products and fine tune them to meet the foreseeable demands of our customers.
To put that philosophy into practice we must invest not only in constant research and development and in skilled men but also in the machines, equipment, manufacturing practices and buildings.
We aim to be the best at everything we do and are actively in pursuit of that goal using all means available to us'.
Current focus of investment is at Colchester and Harrison lathes.
A new Manufacturing Director, Andy Higgins, has joined from the aerospace industry with the specific task of introducing an innovative production system designed to minimise lead times, minimise manufacturing overheads, and ensure technological innovations are easy to implement.
The new system is based primarily on a close-coupling manufacturing system, which pulls machines through the production system rather than MRP, which pushes a machine through.
Employee empowerment is a major element within the system, with the team leader in each section and the men working within it responsible for maintaining and improving the build programme as well as, predictably, build quality.
Bought-in parts, from small items such as nuts and bolts through to major machine parts like chucks and ballscrews, are controlled to ensure immediate availability while eliminating the 'stores' mindset.
Currently, the plant is being reorganised and up-graded, with completion due before Christmas.
Andy said 'This represents a substantial investment, with new plant being installed and the building itself being upgraded but perhaps the most significant investment has been in training.
When we initiated the new production system, we were committed to at least maintaining the existing workforce.
Everyone was actively involved in analysing the status quo and identifying where improvements could be made but, perhaps more importantly, in assessing skills levels and increasing them so that each employee becomes multi-skilled and able to undertake a wide range of work within the plant'.
The latest investment in Colchester and Harrison Lathes follows the œ3 million invested in new plant and equipment, up-graded machines and a new precision grinding facility last year at Crawford Collets and Pratt Burnerd International.
Coincidental with the investment at the workholding manufacturing plant was an investment of almost a million at the Gamet Bearings plant in Colchester, where new machines were installed.
Dr Sweeten said 'We have six manufacturing sites in the UK, one in Heckmondwike (for lathes), one in Colchester (for high precision bearings), three in Halifax (for workholding, fabrications and control systems) and one in Letchworth (for industrial lasers and laser marking systems).
Innovation is the key to their continuing success, and to maintain that needs investment.
Heart, mind - and wallet - we are committed to manufacturing in Britain.
We know that, thanks to the investment we are making and will continue to make in our UK plants, we can compete effectively with any other company any where in the world, can remain at the forefront of manufacturing world-wide, can prosper and thrive.
We hope that other British manufacturers will, like us, appreciate that Britain can be the powerhouse if we commit, if we strive, if we invest'.
Saturday, July 01, 2006
600 Group gives thumbs-up to IMTS show
The 600 Group is reporting excellent results from the IMTS show in Chicago. Three Group companies - Clausing Industrial Inc, Pratt Burnerd America, and Electrox (USA) - all had stands at the show. In addition, Harrison Lathes was also represented on the stand of its distributor REM Sales.
Across the range of Group products, which extends from high technology laser marking machines to lathes, machining centres, and workholding equipment, both the quality and the quantity of enquiries were significantly improved upon the last show.
Group Chief Executive Tony Sweeten said 'It was a lively, buoyant show with serious customers thronging the aisles.
At times, it was almost impossible to walk on to the stands for potential customers showing a serious interest in the machines - for instance we sold 5 Harrison Alpha lathes during the show to new customers.
We believe that the American market is now a vigorous market and one in which our companies are well placed to take full advantage.
As a Group, we concentrate on two things - continual investment in improved performance and research which leads to innovation.
As a result, we have even shorter lead times than we were able to offer at the last show and machine tools and ancillary equipment which have been fine tuned to suit the needs of the customer both now and for the foreseeable future'.
The new Colchester Tornado CNC lathe, which was launched to the US market at the show by Clausing, received great acclaim.
Well suited to the market with both 3 and 5 axis versions, the lathes attracted significant attention and many serious enquiries.
Several Multiturns and many standard Colchesters were also sold during the show and very many orders received.
Clausing, which sells a balanced combination of Colchester lathes, own-manufacture machines (including the popular Richmond machining centre) and machines imported from elsewhere, offers virtually a one-stop shop to the production engineer.
President of the company, Bill Nancarrow said 'This show was up-beat, and was a clear indication that the American market is continuing to pick up well.
The atmosphere was confident and the general mood one of creating further successes by investing in the appropriate machine tools.
At Clausing we are able to offer the most appropriate technology to each individual customer.
In particular, the new five axis Tornado attracted substantial interest and we have many enquiries which we expect to convert to orders in the immediate future.
The three-axis Tornado was also very well received and we are expecting good orders for this machine too.
The new design clearly has strong appeal to the market: we even had distributors approaching us for the opportunity to sell it, a further indication of its potential.
All year we have been finding order levels increasing across the range of industries - general engineering, sub-contractors, medical engineering, aerospace and government industries - and the show seems to have capitalized on the belief that the economic climate is improving and will continue to do so'.
In addition to the success which Clausing enjoyed, a number of orders and many enquiries were received by 600 Machine Tools (the Group's company in Canada) and REM Sales was delighted with the sales and quality of enquiries it achieved.
Pratt Burnerd America, which was launching the new Programmable power chuck and the Self-Contained Power Chuck, doubled the enquiry level compared with the last IMTS and Electrox USA was so inundated with enquiries that after the first day it was forced to bring several additional staff onto the stand to cope with the volume of potential customers.
Across the range of Group products, which extends from high technology laser marking machines to lathes, machining centres, and workholding equipment, both the quality and the quantity of enquiries were significantly improved upon the last show.
Group Chief Executive Tony Sweeten said 'It was a lively, buoyant show with serious customers thronging the aisles.
At times, it was almost impossible to walk on to the stands for potential customers showing a serious interest in the machines - for instance we sold 5 Harrison Alpha lathes during the show to new customers.
We believe that the American market is now a vigorous market and one in which our companies are well placed to take full advantage.
As a Group, we concentrate on two things - continual investment in improved performance and research which leads to innovation.
As a result, we have even shorter lead times than we were able to offer at the last show and machine tools and ancillary equipment which have been fine tuned to suit the needs of the customer both now and for the foreseeable future'.
The new Colchester Tornado CNC lathe, which was launched to the US market at the show by Clausing, received great acclaim.
Well suited to the market with both 3 and 5 axis versions, the lathes attracted significant attention and many serious enquiries.
Several Multiturns and many standard Colchesters were also sold during the show and very many orders received.
Clausing, which sells a balanced combination of Colchester lathes, own-manufacture machines (including the popular Richmond machining centre) and machines imported from elsewhere, offers virtually a one-stop shop to the production engineer.
President of the company, Bill Nancarrow said 'This show was up-beat, and was a clear indication that the American market is continuing to pick up well.
The atmosphere was confident and the general mood one of creating further successes by investing in the appropriate machine tools.
At Clausing we are able to offer the most appropriate technology to each individual customer.
In particular, the new five axis Tornado attracted substantial interest and we have many enquiries which we expect to convert to orders in the immediate future.
The three-axis Tornado was also very well received and we are expecting good orders for this machine too.
The new design clearly has strong appeal to the market: we even had distributors approaching us for the opportunity to sell it, a further indication of its potential.
All year we have been finding order levels increasing across the range of industries - general engineering, sub-contractors, medical engineering, aerospace and government industries - and the show seems to have capitalized on the belief that the economic climate is improving and will continue to do so'.
In addition to the success which Clausing enjoyed, a number of orders and many enquiries were received by 600 Machine Tools (the Group's company in Canada) and REM Sales was delighted with the sales and quality of enquiries it achieved.
Pratt Burnerd America, which was launching the new Programmable power chuck and the Self-Contained Power Chuck, doubled the enquiry level compared with the last IMTS and Electrox USA was so inundated with enquiries that after the first day it was forced to bring several additional staff onto the stand to cope with the volume of potential customers.
Acquisition extends turning capacity
Woodhey Engineering of Bacup, Lancashire, has expanded its capacity to produce high quality components with the acquisition of a Harrison Alpha 1550S manual/CNC lathe.
Specialist turning, milling and machining company, Woodhey Engineering of Bacup, Lancashire, has expanded its capacity to produce high quality components - and opened up important new market sectors - with the acquisition of a Harrison Alpha 1550S manual/CNC lathe. Woodhey, a well-established family-owned business for more than 100 years has successfully operated a Harrison Alpha 550 lathe since 1996, and the new Alpha 1550S has already had a positive impact on the company's business. Woodhey was required to quote for producing a large quantity of isolators for an existing customer which manufactures vibro-piling equipment for ground-breaking machinery, used in the construction industry.
Previously, Woodhey had produced the parts which make up the isolators in either one-off or small batch quantities.
Woodhey's Works Manager, Adrian Briggs, says: 'We wanted to do the work faster.
An existing customer asked us to quote for a larger quantity - between 75 and 100 off items over 12 months, and this was only possible for us with the Alpha 1550S.
The new machine represents a saving of about two hours for each unit compared to a conventional lathe.' He said the new machine had proved 'very easy' for operators at Woodhey to use following their initial training and was already opening up new opportunities.
'We always had good results from the Alpha 550 lathe but we always used to keep away from bulk work.
Now we have the capability to take on new types of orders and customers.
It is an important step forward for our business.' Part of Harrison's world-famous and best-selling Alpha 1000 series which has become the industry standard for manual/CNC lathes, the Alpha 1550S has 550mm swing over bed and up to 3 metres between centres.
Yet just like all other Alpha 1000 machines, it is extremely simple to operate, highly versatile with a wide choice of turning options and manufactured to tool-room standards (DIN 8605) for ultimate precision in large turned components.
Like all Alpha 1000 Series lathes, the 1550S incorporates the unique 'Key to Success' which enables the operator to switch between three separate turning options, namely Alpha mode, Manual Guidance or CNC modes: Alpha mode - the machine's unique software, developed by Harrison, opens up a world of simple semi-automatic machining for stops, tapers, threads, box cycles and contour shapes.
Alpha can be learnt quickly by conventional lathe operators, many of whom have used it to more than double their output.
Manual Guidance - this is ideal for operators who require to produce small batches of complex parts or to generate on-screen graphic representations of the turning operations which can be quickly converted to full CNC programs.
The 'Teach' mode allows movements made using the hand-wheels to be recorded as a program and re-run automatically, while 'Single Cutting' means simple profiles can be generated line by line at the control.
'Cycle Cutting' provides automatic generation of a comprehensive range of cycles which can be linked to develop full programs.
During program development, 3-D graphic simulation allows tool-paths and component profiles to be viewed.
Full CNC mode - enables the Alpha 1550S to operate as a fully functional CNC lathe with a large machining envelope.
CNC programs can either be generated by data input on the keypad or generated off-line (by Harrison's AlphaLink software).
Like all Harrison Alpha 1000 lathes, the 1550S is offered with a wide range of accessories which includes manual, high-accuracy four-way indexing toolpost and automatic bi-directional 8-station disc turret.
The Alpha 1550S, which is available with centre distances of both 2m and 3m, is equipped with 104mm bore spindle mounted in Gamet heavy duty high-precision taper roller bearings and fitted with D1-11 camlock spindle nose to accommodate either manual three- or four-jaw chucks or hydraulically-operated chucks from Pratt Burnerd.
Specialist turning, milling and machining company, Woodhey Engineering of Bacup, Lancashire, has expanded its capacity to produce high quality components - and opened up important new market sectors - with the acquisition of a Harrison Alpha 1550S manual/CNC lathe. Woodhey, a well-established family-owned business for more than 100 years has successfully operated a Harrison Alpha 550 lathe since 1996, and the new Alpha 1550S has already had a positive impact on the company's business. Woodhey was required to quote for producing a large quantity of isolators for an existing customer which manufactures vibro-piling equipment for ground-breaking machinery, used in the construction industry.
Previously, Woodhey had produced the parts which make up the isolators in either one-off or small batch quantities.
Woodhey's Works Manager, Adrian Briggs, says: 'We wanted to do the work faster.
An existing customer asked us to quote for a larger quantity - between 75 and 100 off items over 12 months, and this was only possible for us with the Alpha 1550S.
The new machine represents a saving of about two hours for each unit compared to a conventional lathe.' He said the new machine had proved 'very easy' for operators at Woodhey to use following their initial training and was already opening up new opportunities.
'We always had good results from the Alpha 550 lathe but we always used to keep away from bulk work.
Now we have the capability to take on new types of orders and customers.
It is an important step forward for our business.' Part of Harrison's world-famous and best-selling Alpha 1000 series which has become the industry standard for manual/CNC lathes, the Alpha 1550S has 550mm swing over bed and up to 3 metres between centres.
Yet just like all other Alpha 1000 machines, it is extremely simple to operate, highly versatile with a wide choice of turning options and manufactured to tool-room standards (DIN 8605) for ultimate precision in large turned components.
Like all Alpha 1000 Series lathes, the 1550S incorporates the unique 'Key to Success' which enables the operator to switch between three separate turning options, namely Alpha mode, Manual Guidance or CNC modes: Alpha mode - the machine's unique software, developed by Harrison, opens up a world of simple semi-automatic machining for stops, tapers, threads, box cycles and contour shapes.
Alpha can be learnt quickly by conventional lathe operators, many of whom have used it to more than double their output.
Manual Guidance - this is ideal for operators who require to produce small batches of complex parts or to generate on-screen graphic representations of the turning operations which can be quickly converted to full CNC programs.
The 'Teach' mode allows movements made using the hand-wheels to be recorded as a program and re-run automatically, while 'Single Cutting' means simple profiles can be generated line by line at the control.
'Cycle Cutting' provides automatic generation of a comprehensive range of cycles which can be linked to develop full programs.
During program development, 3-D graphic simulation allows tool-paths and component profiles to be viewed.
Full CNC mode - enables the Alpha 1550S to operate as a fully functional CNC lathe with a large machining envelope.
CNC programs can either be generated by data input on the keypad or generated off-line (by Harrison's AlphaLink software).
Like all Harrison Alpha 1000 lathes, the 1550S is offered with a wide range of accessories which includes manual, high-accuracy four-way indexing toolpost and automatic bi-directional 8-station disc turret.
The Alpha 1550S, which is available with centre distances of both 2m and 3m, is equipped with 104mm bore spindle mounted in Gamet heavy duty high-precision taper roller bearings and fitted with D1-11 camlock spindle nose to accommodate either manual three- or four-jaw chucks or hydraulically-operated chucks from Pratt Burnerd.
Friday, June 30, 2006
Advanced CNC lathe defeats overseas competition
An advanced, CNC lathe has transformed the capability of a small engineering company, so that it is now regularly beating a major Japanese OEM in the competitive replacement machine parts market.
An advanced, British-built Harrison Alpha 1350S lathe has transformed the capability of a small, family-run Staffordshire engineering company, so that it is now taking on - and regularly beating - a major Japanese OE manufacturer in the highly competitive market for replacement machine parts. MPD Engineering of Tamworth, which was formed just five years ago and named after husband-and-wife team, Melanie and Paul Johnson and their eight-year-old son, Devon, was supplied with the two-axis CNC/manual flatbed lathe by Harrison main distributor, Datamach of Coventry. With its 350mm swing, highly sophisticated, yet simple-to-operate touchscreen control based on the successful GE Fanuc 21i-T computerized control system, the Harrison Alpha 1350s has enabled MPD Engineering to achieve significantly better finished results in a fraction of the time taken by its original manual lathe.
'It has made the work so much quicker and an enormous difference to our turnaround times.
We got rid of our old manual lathe after two days with the Harrison.
With the level of work we are now taking on, we would never have been able to keep up.
The speed which we achieve with this machine is clearly the way forward for our company and the standard of finish is unreal.
It is far better than before,' says MPD Engineering Director, Paul Johnson.
He said the company specializes in three distinct market sectors, namely bronze pump gears and stainless steel shafts and regulators for ice-cream mobile dispensing equipment used in ice-cream vans and, secondly, repairs and refurbishment for the plastic injection-moulding industry, including producing lathe-turned sprue bushes for food packaging systems.
But it is in the third category - supplying replacement transmission parts, including gears and sprockets to a range of industrial equipment operators such as fork-lift operators, where MPD Engineering is able to make precise new geared drives, that the company's fortunes have perhaps been boosted most of all by the Harrison Alpha 1350S.
Johnson explains: 'One of our fastest-growing markets is customers with Japanese equipment producing spiral wire for the automotive industry.
Replacement gearbox parts for these machines can take up to four weeks, or even longer, to ship here from Japan.
'Now, with the new lathe we are able to supply them with replacement parts, usually the conical gears in the gearbox, the planet ring and the sun wheel, much more cheaply and much quicker than they could get them before.
It's a sign that more manufacturers are turning to home-based engineering suppliers like ourselves for reliability and value for money.' The Alpha 1350S forms part of Harrison's popular, state-of-the-art S1000 series of CNC/manual lathes, available in five models with up to a maximum 800mm swing.
The S1000 series incorporates the flexibility, speed and ease-of-use of a fully computer-controlled lathe with the extra advantage of easy manual turning.
It is especially suitable for producing reliable, precise medium and high volume turned parts, in semi-automatic or full CNC modes.
A major new feature of the S1000's control capability is its Manual Guide System - a touchscreen accessible cutting programme enabling the full generation of simple cutting profiles and complex automatic programmes to be carried out directly at the machine.
A teach facility is also available, allowing hand wheel-initiated moves to be recorded as a programme and re-run automatically after completion of the first component, while all new programmes generated can be stored to memory for later use or saved to the integral AlphaLink software.
Additionally, all programmes generated in this comprehensive 'Cycle Cutting' mode can be converted to a full CNC programme.
The Alpha range also incorporates a semi-automatic machining capability for stops, taper turning and automatic thread cutting, plus an off-line CAD/CAM machining facility.
One of the heaviest, most powerful lathes in its class, the Alpha S1000S series combines excellent cutting performance and rigidity with quality design and manufacturing for the highest standard of repeatability and long life.
Their high-precision machine beds are hardened to 450 Brinnel prior to grinding, while a PTFE-based (moglice) material is used in key areas for low friction and wear on slides.
All Alpha S1000 lathes use high precision ballscrews, ground and pre-loaded for high accuracy, minimum friction and low maintenance.
An advanced, British-built Harrison Alpha 1350S lathe has transformed the capability of a small, family-run Staffordshire engineering company, so that it is now taking on - and regularly beating - a major Japanese OE manufacturer in the highly competitive market for replacement machine parts. MPD Engineering of Tamworth, which was formed just five years ago and named after husband-and-wife team, Melanie and Paul Johnson and their eight-year-old son, Devon, was supplied with the two-axis CNC/manual flatbed lathe by Harrison main distributor, Datamach of Coventry. With its 350mm swing, highly sophisticated, yet simple-to-operate touchscreen control based on the successful GE Fanuc 21i-T computerized control system, the Harrison Alpha 1350s has enabled MPD Engineering to achieve significantly better finished results in a fraction of the time taken by its original manual lathe.
'It has made the work so much quicker and an enormous difference to our turnaround times.
We got rid of our old manual lathe after two days with the Harrison.
With the level of work we are now taking on, we would never have been able to keep up.
The speed which we achieve with this machine is clearly the way forward for our company and the standard of finish is unreal.
It is far better than before,' says MPD Engineering Director, Paul Johnson.
He said the company specializes in three distinct market sectors, namely bronze pump gears and stainless steel shafts and regulators for ice-cream mobile dispensing equipment used in ice-cream vans and, secondly, repairs and refurbishment for the plastic injection-moulding industry, including producing lathe-turned sprue bushes for food packaging systems.
But it is in the third category - supplying replacement transmission parts, including gears and sprockets to a range of industrial equipment operators such as fork-lift operators, where MPD Engineering is able to make precise new geared drives, that the company's fortunes have perhaps been boosted most of all by the Harrison Alpha 1350S.
Johnson explains: 'One of our fastest-growing markets is customers with Japanese equipment producing spiral wire for the automotive industry.
Replacement gearbox parts for these machines can take up to four weeks, or even longer, to ship here from Japan.
'Now, with the new lathe we are able to supply them with replacement parts, usually the conical gears in the gearbox, the planet ring and the sun wheel, much more cheaply and much quicker than they could get them before.
It's a sign that more manufacturers are turning to home-based engineering suppliers like ourselves for reliability and value for money.' The Alpha 1350S forms part of Harrison's popular, state-of-the-art S1000 series of CNC/manual lathes, available in five models with up to a maximum 800mm swing.
The S1000 series incorporates the flexibility, speed and ease-of-use of a fully computer-controlled lathe with the extra advantage of easy manual turning.
It is especially suitable for producing reliable, precise medium and high volume turned parts, in semi-automatic or full CNC modes.
A major new feature of the S1000's control capability is its Manual Guide System - a touchscreen accessible cutting programme enabling the full generation of simple cutting profiles and complex automatic programmes to be carried out directly at the machine.
A teach facility is also available, allowing hand wheel-initiated moves to be recorded as a programme and re-run automatically after completion of the first component, while all new programmes generated can be stored to memory for later use or saved to the integral AlphaLink software.
Additionally, all programmes generated in this comprehensive 'Cycle Cutting' mode can be converted to a full CNC programme.
The Alpha range also incorporates a semi-automatic machining capability for stops, taper turning and automatic thread cutting, plus an off-line CAD/CAM machining facility.
One of the heaviest, most powerful lathes in its class, the Alpha S1000S series combines excellent cutting performance and rigidity with quality design and manufacturing for the highest standard of repeatability and long life.
Their high-precision machine beds are hardened to 450 Brinnel prior to grinding, while a PTFE-based (moglice) material is used in key areas for low friction and wear on slides.
All Alpha S1000 lathes use high precision ballscrews, ground and pre-loaded for high accuracy, minimum friction and low maintenance.
Chucking package included with five axes
A one-hit capability, five-axis mill/turning chucking centre with the advantage of automatic part transfer to a second operation sub-spindle is able to provide single cycle machining for parts having up to a 200 mm turned diameter. Now available from Colchester Sales, as a ready-to-turn package, the latest Colchester T6MS chucker follows the latest livery and futuristic guarding design that now distinguishes the Colchester Tornado range. It has the option of a 170 mm or 210 mm chuck size, and the main spindle is powered by 15 kW motor with a 130 mm chuck 5.5 kW sub-spindle.
With a maximum part length capacity of 470 mm between both spindle chuck jaws, the machine has the capability to initiate in-phase radial C-axis rotation that enables in-cycle synchronised spindle kissing for part exchange.
A 12 station, all-driven 3.7 kW, 30 VDI mill/turn turret services both chucking spindles controlled by a totally integrated Fanuc 18i-TB CNC unit.
The machine is compact, having an identical footprint to a two or three axis Tornado version and has a swing over bed of 440 mm, a maximum turning diameter of 200 mm by 200 mm turning length with a maximum turned length (Z-axis) of 450 mm.
The sub-spindle has a spindle bore of 43 mm and a fully synchronised drive with the main spindle to provide on-the-fly part exchange which is carried out at a rapid traverse rate of 30 m/min.
There is a choice of main and sub-spindle speeds of 4,000 or 6,000 revs/min and positional accuracy is plus/minus 0.005 mm.
Repeatability is within plus/minus 0.002 mm.
The Tornado T6 MS is also available in a robot-loaded, Lights-out unmanned package, as well as in a bar fed configuration.
In the Lights-out package, swarf conveyor, tool monitoring and sister tool replacement, production scheduling software and in-process gauging with automatic offset adjustment are all included as standard.
With a maximum part length capacity of 470 mm between both spindle chuck jaws, the machine has the capability to initiate in-phase radial C-axis rotation that enables in-cycle synchronised spindle kissing for part exchange.
A 12 station, all-driven 3.7 kW, 30 VDI mill/turn turret services both chucking spindles controlled by a totally integrated Fanuc 18i-TB CNC unit.
The machine is compact, having an identical footprint to a two or three axis Tornado version and has a swing over bed of 440 mm, a maximum turning diameter of 200 mm by 200 mm turning length with a maximum turned length (Z-axis) of 450 mm.
The sub-spindle has a spindle bore of 43 mm and a fully synchronised drive with the main spindle to provide on-the-fly part exchange which is carried out at a rapid traverse rate of 30 m/min.
There is a choice of main and sub-spindle speeds of 4,000 or 6,000 revs/min and positional accuracy is plus/minus 0.005 mm.
Repeatability is within plus/minus 0.002 mm.
The Tornado T6 MS is also available in a robot-loaded, Lights-out unmanned package, as well as in a bar fed configuration.
In the Lights-out package, swarf conveyor, tool monitoring and sister tool replacement, production scheduling software and in-process gauging with automatic offset adjustment are all included as standard.
'Lights-out' mill-turn package seals contract
A 'lights-out' mill-turn package giving an unmanned running capability secured a GBP 40,000/year contract that would not have been quoted for before the installation.
Committing to purchase his fifth Colchester Tornado in five years at MACH 2004 but this time a 'lights-out' package giving an unmanned running capability, managing director Roger Metcalfe of Cleveland Components, Skelton in Cleveland maintains for his progressive business build-up and for the type of parts he has to produce, he has not been able to find a better investment in turning machines. And, as a result of the exhibition purchase which for Cleveland Components proved to be very timely, Roger Metcalfe almost immediately secured a GBP 40,000 a year contract that he would not have been able to even quote for before the installation. With four Tornados already installed since the company was set up in March 1999 alongside four very different makes of vertical machining centre, Metcalfe admits to having deep concerns over 'comfort' buying.
'I went to MACH at the NEC in Birmingham with a completely open mind and carefully weighed up features and specifications of different lathes against the type of work we produce and the type of components we want to make in the future.
Always in mind, of course, is the installed price,' he insists but has to admit: 'No other machine tool supplier came close!' Adding to his concerns over the 'comfort' factor was that he strongly believed a lathe was for turning and a machining centre was for milling.
This gave his company the best flexibility for production and allowed most to be achieved from producing parts individually on each machine type.
However, Colchester Sales convinced him that he should think wider than two-axis turning and that for his type of parts he would never look back even though the Tornado 120M, in a 'Lights-out' unmanned mill/turn centre package, was more expensive than the two-axis machine he felt he was in the market for.
To which he now adds: 'We cannot believe the benefits of three-axis' and expresses his feelings by waving the GBP 40,000 contract purely won as a result of the Tornado 120M, that he would never have been competitive to bid for - let alone win.
Cleveland Components has grown from just two people to 13 in five years and had sales in 2003 of over GBP 700,000.
With the new Tornado 120M Metcalfe is now moving the business to create a machining cell giving unmanned running between shifts and at night.
To achieve this he can program the machine using ColCAM, the Colchester developed off-line programming software, set up the tooling, tool monitoring limits and production scheduling software, program the Renishaw probing routines, load the bar, press the button and let it go.
The company is very active and has developed a very loyal and 'live' customer list of over 100 companies.
At the day of the visit, 25 different customers had orders on the job list from automotive and motorsport, telecoms, aerospace, chemical and medical sectors in batches that varied between 10 and 5,000.
Originally business was generated locally and in the North East but as the company expanded customers are now based all over the UK and materials processed vary from steel and stainless steel, copper, brass and aluminium as well as the occasional exotic steel.
It was this background of customers, diverse parts and materials that helped Metcalfe follow his repeat purchases of Colchester machines.
He maintains: 'I identified the type of machine to give accuracy and repeatability but I had to be very aware of commercial pressures and with the Tornado the rate per hour I can charge is very competitive.' His progression of purchase started with a Tornado A50 and bar feed package in 1999.
After moving to the current premises when they were first built and within six months of setting up Cleveland Components, he added a second Tornado, this time a 100 chucker, followed by a Tornado A90 again with a bar feed package.
At that point in the expansion of the business he found enquiries and orders were beginning to be won from blue chip companies.
A larger capacity Tornado 200 was then installed which led to the Tornado 120 three-axis mill/turn 'lights-out' package machine decision at MACH 2004.
Metcalfe readily admits to it being a speculative purchase but has turned out to be one of the most rewarding made because of the opportunities it has opened up.
'It's my busiest machine and most importantly, a point I never considered when placing the order, is that it has completely changed the workload on the machining centres enabling us to take on further work for them.' Lead times have been dramatically reduced which has been helped by the ColCAM off-line programming package bought with the machine.
He now maintains: 'You would not believe how differently we work.
It is all down to the ability to mill and turn in the same cycle and being able to set and run parts without having to be involved except to oversee and prepare the next batch run.' The Tornado 120M 'Lights-out' package has a 52mm bar capacity and 12 driven tool positions and incorporates the Colchester patented Duo-stable polymer concrete base configuration that gives some 25 per cent improvement in damping.
This also enables the machine to reach running temperature faster and provides a much more stable cutting platform especially when mill/turning.
High stability is important with the all-driven turret being powered by a 3.7kW motor giving 5,000 rev/min and with the disc brake on the spindle to hold position.
This enables Roger Metcalfe's setter to take effective cuts without problems of vibration, chatter and movement when milling.
The 'lights-out' package with Fanuc 21i-Ta control includes the Colchester developed MBF bar feed system programmable at the control, a parts-catcher and integral swarf conveyor, axis torque monitoring, on-board production control software, the ColCAM on-machine graphics-based programming software and Renishaw's component probing system.
A typical part produced by Cleveland Components is a complex valve housing out of 25mm aluminium bar in batches of 250.
The part requires six driven tools, three applied axially and three radially.
The part has a 9 mm off-centre profiled boss of 7mm diameter which has a drilled and tapped M5 x 0.8 hole 7mm deep and a blended profile with a 6mm radius to the main component centre line.
A cross drilled hole of 2mm diameter also breaks into two centre bores which are 8mm and 5mm diameter which also have a further cross hole breaking through of 5mm diameter.
There are also grooves, radii and chamfers.
The part is turned and milled complete in under three minutes but as Roger Metcalfe admits, although he can machine 90 per cent of the part in one cycle, he still has to perform a second operation to finish the part- off face and drill and tap another hole in the end.
'I need a subspindle machine now and the new Tornado T6MS is going on the shopping list,' he insists.
'It's no longer lathes for turning, machining centres for milling - I want a part in one cycle.
It's a natural progression and can't happen soon enough,' he concludes.
Committing to purchase his fifth Colchester Tornado in five years at MACH 2004 but this time a 'lights-out' package giving an unmanned running capability, managing director Roger Metcalfe of Cleveland Components, Skelton in Cleveland maintains for his progressive business build-up and for the type of parts he has to produce, he has not been able to find a better investment in turning machines. And, as a result of the exhibition purchase which for Cleveland Components proved to be very timely, Roger Metcalfe almost immediately secured a GBP 40,000 a year contract that he would not have been able to even quote for before the installation. With four Tornados already installed since the company was set up in March 1999 alongside four very different makes of vertical machining centre, Metcalfe admits to having deep concerns over 'comfort' buying.
'I went to MACH at the NEC in Birmingham with a completely open mind and carefully weighed up features and specifications of different lathes against the type of work we produce and the type of components we want to make in the future.
Always in mind, of course, is the installed price,' he insists but has to admit: 'No other machine tool supplier came close!' Adding to his concerns over the 'comfort' factor was that he strongly believed a lathe was for turning and a machining centre was for milling.
This gave his company the best flexibility for production and allowed most to be achieved from producing parts individually on each machine type.
However, Colchester Sales convinced him that he should think wider than two-axis turning and that for his type of parts he would never look back even though the Tornado 120M, in a 'Lights-out' unmanned mill/turn centre package, was more expensive than the two-axis machine he felt he was in the market for.
To which he now adds: 'We cannot believe the benefits of three-axis' and expresses his feelings by waving the GBP 40,000 contract purely won as a result of the Tornado 120M, that he would never have been competitive to bid for - let alone win.
Cleveland Components has grown from just two people to 13 in five years and had sales in 2003 of over GBP 700,000.
With the new Tornado 120M Metcalfe is now moving the business to create a machining cell giving unmanned running between shifts and at night.
To achieve this he can program the machine using ColCAM, the Colchester developed off-line programming software, set up the tooling, tool monitoring limits and production scheduling software, program the Renishaw probing routines, load the bar, press the button and let it go.
The company is very active and has developed a very loyal and 'live' customer list of over 100 companies.
At the day of the visit, 25 different customers had orders on the job list from automotive and motorsport, telecoms, aerospace, chemical and medical sectors in batches that varied between 10 and 5,000.
Originally business was generated locally and in the North East but as the company expanded customers are now based all over the UK and materials processed vary from steel and stainless steel, copper, brass and aluminium as well as the occasional exotic steel.
It was this background of customers, diverse parts and materials that helped Metcalfe follow his repeat purchases of Colchester machines.
He maintains: 'I identified the type of machine to give accuracy and repeatability but I had to be very aware of commercial pressures and with the Tornado the rate per hour I can charge is very competitive.' His progression of purchase started with a Tornado A50 and bar feed package in 1999.
After moving to the current premises when they were first built and within six months of setting up Cleveland Components, he added a second Tornado, this time a 100 chucker, followed by a Tornado A90 again with a bar feed package.
At that point in the expansion of the business he found enquiries and orders were beginning to be won from blue chip companies.
A larger capacity Tornado 200 was then installed which led to the Tornado 120 three-axis mill/turn 'lights-out' package machine decision at MACH 2004.
Metcalfe readily admits to it being a speculative purchase but has turned out to be one of the most rewarding made because of the opportunities it has opened up.
'It's my busiest machine and most importantly, a point I never considered when placing the order, is that it has completely changed the workload on the machining centres enabling us to take on further work for them.' Lead times have been dramatically reduced which has been helped by the ColCAM off-line programming package bought with the machine.
He now maintains: 'You would not believe how differently we work.
It is all down to the ability to mill and turn in the same cycle and being able to set and run parts without having to be involved except to oversee and prepare the next batch run.' The Tornado 120M 'Lights-out' package has a 52mm bar capacity and 12 driven tool positions and incorporates the Colchester patented Duo-stable polymer concrete base configuration that gives some 25 per cent improvement in damping.
This also enables the machine to reach running temperature faster and provides a much more stable cutting platform especially when mill/turning.
High stability is important with the all-driven turret being powered by a 3.7kW motor giving 5,000 rev/min and with the disc brake on the spindle to hold position.
This enables Roger Metcalfe's setter to take effective cuts without problems of vibration, chatter and movement when milling.
The 'lights-out' package with Fanuc 21i-Ta control includes the Colchester developed MBF bar feed system programmable at the control, a parts-catcher and integral swarf conveyor, axis torque monitoring, on-board production control software, the ColCAM on-machine graphics-based programming software and Renishaw's component probing system.
A typical part produced by Cleveland Components is a complex valve housing out of 25mm aluminium bar in batches of 250.
The part requires six driven tools, three applied axially and three radially.
The part has a 9 mm off-centre profiled boss of 7mm diameter which has a drilled and tapped M5 x 0.8 hole 7mm deep and a blended profile with a 6mm radius to the main component centre line.
A cross drilled hole of 2mm diameter also breaks into two centre bores which are 8mm and 5mm diameter which also have a further cross hole breaking through of 5mm diameter.
There are also grooves, radii and chamfers.
The part is turned and milled complete in under three minutes but as Roger Metcalfe admits, although he can machine 90 per cent of the part in one cycle, he still has to perform a second operation to finish the part- off face and drill and tap another hole in the end.
'I need a subspindle machine now and the new Tornado T6MS is going on the shopping list,' he insists.
'It's no longer lathes for turning, machining centres for milling - I want a part in one cycle.
It's a natural progression and can't happen soon enough,' he concludes.
Thursday, June 29, 2006
Rotary Tables and Rotary Stages
A rotary table is designed to be used in conjunction with vertical mills. When a rotary table is put on a vertical mill what you create is a machine that is theoretically capable of reproducing itself.
A standard milling machine set-up usually involves aligning the work with the table and then with the spindle. The table can be accurately moved with the hand wheels making this a simple operation for most. Aligning a part on a rotary table however can be difficult because the work has to be clamped into position. This is not always easy when you are working alone.
Most experts suggest that you start by doing the rotary table work first which can eliminate the need for precision aligning. Aligning the milling spindle with the rotary table can be done by indicating the hole in the center of the rotary table. You then need to spot drill the center on the work you wish to have line up with the rotary table. Finally put a pointer in the spindle that is accurate. After doing this set the work under the spindle and lower the head until it engages with the center mark at this point clamp the part down. And there you have it, locked and ready to work with.
Rotary stages are used in industrial robots, fiber optics and photonics, vision systems, machine tools, assembly, semiconductor equipment, medical component laser machining, electronic manufacturing, and other high-performance industrial automation applications. Rotary stages provide the best angular positioning and velocity control. Applications range from indexing to high-speed laser machining to precision wafer inspection. All of these applications are fine tuned to the best numbers possible using rotary stages.
There are several types of rotary stages at this point in the game however the ones getting the most press are the laser guided rotary stages. Utilizing lasers helps create the most absolute positioning to date. Some of the newer rotary stages are ideal for applications that require X, Y and q degrees of movement for ambient and high vacuum environments. They tend to feature high resolution, high stability as well as being available for ambient and high vacuum environments. Experts also agree that having the choice of lateral and rotational degrees of freedom also lends that extra precision that is needed in delicate jobs as well as the strength for larger projects.
Mazda MX 6: Shining Amidst A New Trend
Who does not know what a Mazda is? Mazda has certainly been one of the most popular and most recognized vehicle brands the world over. A person who has been living in a world where there are automobiles and vehicles and cars would certainly know what a Mazda is. This vehicle brand is probably very popular because of the type and kind of cars that they craft and produce. The vehicles are made of quality materials, are unique, and can really do perform well.
This vehicle company was founded in the year 1920. It was known then as the Toyo Cork Kogyo Co., Ltd. and it was led by Jujiro Matsuda. The company’s first products were machine tools, however it later on shifted to producing automobiles. The very first vehicle that they produced was the Mazda Go and it was done in 1931. Uniquely, unlike any other vehicle, the Mazda Go actually held only three wheels. Even if the company has been producing vehicles since 1931, Mazda was only fully and officially recognized as an automobile maker in 1960. This time, the company had already been able to produce their very first car with four wheels. And they named it the Mazda R380 coupe.
One of the vehicles that run under the popular brand of the Mazda company is the Mazda MX 6 which was introduced in the early 1988. This vehicle holds performance, versatility and style amidst the trend in the automobile world where sports coupes were running low and the world is slowly becoming invaded by sport utility vehicles. But the Mazda MX 6 was a sports coupe and yet it continues to shine amidst the current trend that time.
The Mazda MX 6 made its way to public knowledge through the Auto Alliance which was actually a joint business enterprise of Mazda and Ford. The sports coupe, Mazda MX 6, held auto parts that were mostly the very same ones that the Ford Probe used. Because of this, the Mazda MX 6 and the Ford Probe were considered to be vehicle twins. Making this vehicle unique was that the designs were actually based on a concept car in the early 1980’s. It held a GD platform. It was also made available in several trims which comprised of the LX, the DX, the LE, and the GT. The power of this vehicle comes from a 2.2 liter SOHC Mazda F2 engine which held four cylinders. This engine has the capacity to produce 110 horsepower. A turbocharged version of this very same engine could be found mounted on the Mazda MX 6 GT trim. The turbocharged version can produce some 145 units of horsepower.
Come the second generation of the Mazda MX 6. The new ones held engines that were capable of producing more power. And because of that, it also was very much capable of giving a more impressive performance. For this new batch, the engines that were offered included a 2.0 liter FS engine with four inline cylinders capable of making some 118 horsepower, and the 2.5 liter V6 engine that could produce some 164 to 170 units of horsepower.
Tools - Machine Tools
The definition of a machine tool, if you look in the dictionary, is a powered machine used for cutting or shaping or finishing metals or other materials. This actually applies to a wide variety of tools such as a broach, drill, gear shaper, hobbing machine, lathe, milling machine, shaper, and grinder.
Of course this definition doesn't really describe the usefulness of these type of tools. So we'll try to do just that in this article.
Most machine tools, also by definition, are tools that are tools that use a power source. In other words, not operated manually. But there are some tools that are considered machine tools that are operated by hand.
The first, what were considered machine tools, were actually made for the purpose of making other tools. These tools removed the human element from the process of stamping these tools by hand. Instead they were now stamped by machines.
The first lathe machine tools were invented in 1751 by Jacques de Vaucanson. He was the very first to mount the cutting instrument of the tool on a mechanically adjustable head. This took the tool out of the hands of the operator.
Machine tools can actually be powered by a number of sources. Aside from human and animal power, the energy for these tools can be captured from waterwheels and steam engines, in the early days, and finally electricity today. The Industrial Revolution had a huge impact on the progress made with machine tools.
Machine tools can be manually operated or automatically controlled. The very early machine tools used flywheels to stabilize their motion. They also had complex systems of gears and levers to control the machine and whatever piece it was that it was working on.
After World War II a new advanced machine was made called the numerical control machine. This machine used a series of numbers punched on paper tape or punch cards that controlled their motion.
In the 1960s, computers were then added to the function of making these machines work. These computers gave more flexibility to the process. These machines became known as computer numerical control machines and they could repeat the same set of instructions over and over similar to an assembly line. These machines could produce pieces that were much more complex than anything produced by even the most skilled tool operator.
It wasn't long before these machines could automatically change the cutting and shaping tools that were being used in the process. To give an example, a drill machine might contain a magazine or cartridge with a number of drill bits. These bits could be used for producing holes of different sizes. Before it was automated, operators would have to manually change the bit in order to drill a different size hole. Today, we have the technology to create a machine that can alternate the drill bits by computer program control.
The truth is, without machine tools, many of the things that we are able to make today would be either tool difficult, too costly or simply impossible to make.
Wednesday, June 28, 2006
CNC lathe reduces work cycles by 12%
In searching for a robust, high build specification turning centre, a machine shop found a slant bed CNC lathe that has since reduced cycle times on tough, complex parts by 12 per cent.
In searching for a robust, high build specification turning centre, a machine shop found a slant bed CNC lathe that has since reduced cycle times by 12 per cent. When Martin Beer, general manager at Plymouth-based specialist sub-contractor PTG Precision Engineers, wanted to increase capacity and throughput in line with customer improvement projects, his search centred on a robust, high build specification turning centre that could cope with the aggressive machining of cast iron components. After a review of several machines, he opted for a Super Kia Turn SKT300 two-axis slant bed lathe from Ward CNC of Sheffield - and not only is the machine satisfying PTG's demanding production routines, but it has also reduced cycle times by 12 per cent.
PTG has been established since 1977 and has evolved from a small toolmaking company into one of the most valued and progressive sub-contractors in the UK.
PTG is currently introducing lean manufacturing throughout its operation and continues to maintain high quality standards, including ISO 9001:2000.
'We have a fair spread of customers throughout industry including companies that manufacture hydraulic motors and pumps, compressor manufacturers as well as a customer base in the valve industry,' Beer explains.
'Recently we have been keen to enter into partnership agreements with many of our customers and suppliers, so that we can forecast further ahead using Kanban techniques.
To help ensure we had sufficient capacity to introduce such a method we required another CNC turning centre.' However, no ordinary turning centre would suffice.
At PTG, much of the machining is based on medium-to-high complexity cast iron or SG (spheroidal graphite) iron gear casing components.
This required a robust machine with enough 'grunt', as Beer describes it, to cope with the rigours of such tough materials in the aggressive fashion required to match the company's high productivity demands.
'We looked at turning centres from several suppliers,' he says, 'but when we saw the robust build quality of the Kia we knew we had found our solution.
Even more so when the machine's excellent value for money high-specification and support were added to the equation.' This latter is a point that Beer is keen to elaborate.
'Ward CNC has been first class.
The machine was delivered and installed on time, and commissioning and training went without hitch.
I have to say that since then (August 2004) the Kia has been very reliable.' Also significant is the fact that the machine is arranged in a production flowline, supplying parts to machining centres across a six-day, double shift work pattern.
'It means that reliability and speed of manufacture are key - and the power of the machine in combination with high technology insert grade tooling has enabled us to reduce cycle times by around 12 per cent.' With a 22/26kW spindle motor producing 3,000 rev/min, the SKT300 has a swing over the bed of 750mm, a maximum turning length of 720mm and a 90mm diameter bar capacity.
Feed rates are 20m/min and 24m/min in X and Z axes, respectively.
Featuring a 12-tool turret and a two-stepped geared headstock for high torque, heavy cutting - and optional programmable tailstock - the Fanuc-controlled SKT300 is designed to minimise non-cutting time.
Its single-piece cast construction boasts a three-layer solid bed and box ways on all axes.
The machine is fitted with a Q-Setter for quick tool compensation as standard.
'The Kia has been excellent,' concludes Beer.
'We have no complaints, and I wouldn‚t hesitate in recommending the machine.'
In searching for a robust, high build specification turning centre, a machine shop found a slant bed CNC lathe that has since reduced cycle times by 12 per cent. When Martin Beer, general manager at Plymouth-based specialist sub-contractor PTG Precision Engineers, wanted to increase capacity and throughput in line with customer improvement projects, his search centred on a robust, high build specification turning centre that could cope with the aggressive machining of cast iron components. After a review of several machines, he opted for a Super Kia Turn SKT300 two-axis slant bed lathe from Ward CNC of Sheffield - and not only is the machine satisfying PTG's demanding production routines, but it has also reduced cycle times by 12 per cent.
PTG has been established since 1977 and has evolved from a small toolmaking company into one of the most valued and progressive sub-contractors in the UK.
PTG is currently introducing lean manufacturing throughout its operation and continues to maintain high quality standards, including ISO 9001:2000.
'We have a fair spread of customers throughout industry including companies that manufacture hydraulic motors and pumps, compressor manufacturers as well as a customer base in the valve industry,' Beer explains.
'Recently we have been keen to enter into partnership agreements with many of our customers and suppliers, so that we can forecast further ahead using Kanban techniques.
To help ensure we had sufficient capacity to introduce such a method we required another CNC turning centre.' However, no ordinary turning centre would suffice.
At PTG, much of the machining is based on medium-to-high complexity cast iron or SG (spheroidal graphite) iron gear casing components.
This required a robust machine with enough 'grunt', as Beer describes it, to cope with the rigours of such tough materials in the aggressive fashion required to match the company's high productivity demands.
'We looked at turning centres from several suppliers,' he says, 'but when we saw the robust build quality of the Kia we knew we had found our solution.
Even more so when the machine's excellent value for money high-specification and support were added to the equation.' This latter is a point that Beer is keen to elaborate.
'Ward CNC has been first class.
The machine was delivered and installed on time, and commissioning and training went without hitch.
I have to say that since then (August 2004) the Kia has been very reliable.' Also significant is the fact that the machine is arranged in a production flowline, supplying parts to machining centres across a six-day, double shift work pattern.
'It means that reliability and speed of manufacture are key - and the power of the machine in combination with high technology insert grade tooling has enabled us to reduce cycle times by around 12 per cent.' With a 22/26kW spindle motor producing 3,000 rev/min, the SKT300 has a swing over the bed of 750mm, a maximum turning length of 720mm and a 90mm diameter bar capacity.
Feed rates are 20m/min and 24m/min in X and Z axes, respectively.
Featuring a 12-tool turret and a two-stepped geared headstock for high torque, heavy cutting - and optional programmable tailstock - the Fanuc-controlled SKT300 is designed to minimise non-cutting time.
Its single-piece cast construction boasts a three-layer solid bed and box ways on all axes.
The machine is fitted with a Q-Setter for quick tool compensation as standard.
'The Kia has been excellent,' concludes Beer.
'We have no complaints, and I wouldn‚t hesitate in recommending the machine.'
Lower cost lathe turns IDs within +/-2 micron
A CNC lathe, costing 30% less than its predecessor, is turning the internal form of diamond wheel dresser moulds to within a +/-2 micron tolerance to meet growing deamnd.
Lower cost lathe machines mould IDs within +/-2 micron A CNC lathe, costing 30% less than its predecessor, is turning the internal form of diamond wheel dresser moulds to within +/-2 micron tolerance. A Daewoo lathe from Mills Manufacturing Technology has been installed at Tyrolit, Crawley, to turn the internal form of bespoke diamond roller dresser moulds to within +/-2 micron tolerance. Over 80 per cent of the dressers are for sharpening the profile of Viper and conventional creep-feed grinding wheels used for machining the tip and root features on aero engine hot-end turbine blades, which are produced from nickel and other exotic alloys.
Other applications include high precision roller dressers for grinding wheels used in the manufacture of land-based turbine blades, bearings including double-track types, saw blades and automotive components such as gear trains.
Around a third of production is exported, Israel and China being particularly buoyant markets at present.
Commented Norman Crown, Tyrolits Technical Manager - Roller Dresser Unit, 'We are expecting a 70 per cent increase in throughput at Crawley within the next 12 months as our parent company in Austria transfers its dresser production to the UK to make way for manufacture of a new product over there.
So we needed to increase our mould turning capacity by installing a second lathe.
The decision was made to buy a Daewoo Puma 240LC, as the cost was 30 per cent less than a new version of the Japanese turning machine we have used for the same job since we set up operations on this site in September 2003 - yet trials showed that the Korean-built machine was just as accurate'.
Accuracy is the watchword in turbine blade production.
Engine manufacturers stipulate a very tight tolerance on the critical fir tree root form, often extending this tolerance to all dimensions on the root and tip.
The form on the grinding wheel, and consequently that of the dresser, needs to be within the same tolerance.
This applies not only to the internal profile of the dresser mould but also to the concentricity of internal features with the outside diameter, which can be up to 250mm.
Profile accuracy is verified using a contour measuring machine, on which every turned mould is checked.
The measured trace is aligned on computer screen as a best fit within a tolerance band taken as DXF output from the CAD model of the dresser, or of the component that will eventually be ground.
The system shows that Tyrolit routinely holds +/-2 microns on mould profile using the Daewoo lathe, well within tolerance, eliminating the need to diamond lap the resulting dresser, which is time consuming and reduces its service life.
The CAD model is normally used to download programs to the Daewoo lathe via Pathtrace EdgeCam software and a suitable post-processor.
Sometimes if the program is simple, the X,Y co-ordinates generated by the CAD system are entered by the operator into the Fanuc control, reducing the load on the CAD/CAM department.
The 10-station turret of the Puma 240 LC lathe is large enough to house boring bars for turning the majority of moulds produced at Crawley, so the indexable carbide insert tools are accurately clamped and rarely exchanged.
The bed is extended on this lathe model to allow the long boring bars to gain access to the inside of moulds used to make the wider Tyrolit dressers.
Average diameter of the finished product is around 130 to 150mm, although it can be as low as 50mm for some Viper grinding applications; and width is normally 50 to 60mm.
Tyrolit dressers are made using the industry-standard method of reverse-plating, which results in a nickel-based matrix carrying industrial diamond grit, with natural diamonds set by hand around the periphery of the dresser where there are sharp changes in the contour.
A finished roller dresser can easily cost GBP 1,500, which is why customers normally leave ordering a new one to the last minute.
Tyrolit prides itself on turning round quotes in 24 hours and keeping lead times short six weeks for standard deliveries.
Purchase of the Daewoo lathe will mean that the Crawley facility will continue to provide this level of service when production is transferred from Austria.
Lower cost lathe machines mould IDs within +/-2 micron A CNC lathe, costing 30% less than its predecessor, is turning the internal form of diamond wheel dresser moulds to within +/-2 micron tolerance. A Daewoo lathe from Mills Manufacturing Technology has been installed at Tyrolit, Crawley, to turn the internal form of bespoke diamond roller dresser moulds to within +/-2 micron tolerance. Over 80 per cent of the dressers are for sharpening the profile of Viper and conventional creep-feed grinding wheels used for machining the tip and root features on aero engine hot-end turbine blades, which are produced from nickel and other exotic alloys.
Other applications include high precision roller dressers for grinding wheels used in the manufacture of land-based turbine blades, bearings including double-track types, saw blades and automotive components such as gear trains.
Around a third of production is exported, Israel and China being particularly buoyant markets at present.
Commented Norman Crown, Tyrolits Technical Manager - Roller Dresser Unit, 'We are expecting a 70 per cent increase in throughput at Crawley within the next 12 months as our parent company in Austria transfers its dresser production to the UK to make way for manufacture of a new product over there.
So we needed to increase our mould turning capacity by installing a second lathe.
The decision was made to buy a Daewoo Puma 240LC, as the cost was 30 per cent less than a new version of the Japanese turning machine we have used for the same job since we set up operations on this site in September 2003 - yet trials showed that the Korean-built machine was just as accurate'.
Accuracy is the watchword in turbine blade production.
Engine manufacturers stipulate a very tight tolerance on the critical fir tree root form, often extending this tolerance to all dimensions on the root and tip.
The form on the grinding wheel, and consequently that of the dresser, needs to be within the same tolerance.
This applies not only to the internal profile of the dresser mould but also to the concentricity of internal features with the outside diameter, which can be up to 250mm.
Profile accuracy is verified using a contour measuring machine, on which every turned mould is checked.
The measured trace is aligned on computer screen as a best fit within a tolerance band taken as DXF output from the CAD model of the dresser, or of the component that will eventually be ground.
The system shows that Tyrolit routinely holds +/-2 microns on mould profile using the Daewoo lathe, well within tolerance, eliminating the need to diamond lap the resulting dresser, which is time consuming and reduces its service life.
The CAD model is normally used to download programs to the Daewoo lathe via Pathtrace EdgeCam software and a suitable post-processor.
Sometimes if the program is simple, the X,Y co-ordinates generated by the CAD system are entered by the operator into the Fanuc control, reducing the load on the CAD/CAM department.
The 10-station turret of the Puma 240 LC lathe is large enough to house boring bars for turning the majority of moulds produced at Crawley, so the indexable carbide insert tools are accurately clamped and rarely exchanged.
The bed is extended on this lathe model to allow the long boring bars to gain access to the inside of moulds used to make the wider Tyrolit dressers.
Average diameter of the finished product is around 130 to 150mm, although it can be as low as 50mm for some Viper grinding applications; and width is normally 50 to 60mm.
Tyrolit dressers are made using the industry-standard method of reverse-plating, which results in a nickel-based matrix carrying industrial diamond grit, with natural diamonds set by hand around the periphery of the dresser where there are sharp changes in the contour.
A finished roller dresser can easily cost GBP 1,500, which is why customers normally leave ordering a new one to the last minute.
Tyrolit prides itself on turning round quotes in 24 hours and keeping lead times short six weeks for standard deliveries.
Purchase of the Daewoo lathe will mean that the Crawley facility will continue to provide this level of service when production is transferred from Austria.
Universal CNC lathes are high-tech
A wealth of 'high-tech' features in universal CNC lathes include top-of-the-range Fanuc or Siemens control with graphical user interface and 3D real-time simulation.
The latest NEF universal lathes from DMG provide top performance from a wealth of high-tech features at an unbeatable price. Successive generations of the NEF brand have brought users excellent value for money and with the new 400 and 600 range, whose prices start at just GBP 31,000, this tradition continues. No other entry-level lathe in this price bracket can match these new models for their quality, reliability and profit potential.
This price includes Fanuc 210i CNC control with Manual Guide, manual 3 jaw chuck (200mm), 8 station turret and tailstock with life centre.
Examples of the features that are atypical in this class of machine include the pivoting DMG SlimLinePanel with 15in TFT screen feature a top-of-the-range Fanuc or Siemens control with graphical user interface and 3D real-time simulation.
Rotational speeds are up to 4,000 rev/min with up to 24kW of drive power and 720Nm torque.
Not to be found on any other entry-level lathe is the 30 deg inclined four-track bed designed for optimal chip clearance and excellent accessibility.
High flexibility and productivity are assured thanks to a large working area and features such as a traversable steady rest and high-speed, 8-station turret.
As a result chucking components up to 55mm and shaft sections up to 1200mm in length can be machined in the shortest time.
The digital drive on the main spindle and dynamically stable linear guideways make a significant contribution to the high precision and excellent surface quality achievable on the new NEF universal lathes.
Manufacturing flexibility is assured by a traversable tailstock with hydraulic quill.
Other notable features are integrated safety systems and a low space requirement.
This fully enclosed machine series comes in a space green finish; metallic optional.
The latest NEF universal lathes from DMG provide top performance from a wealth of high-tech features at an unbeatable price. Successive generations of the NEF brand have brought users excellent value for money and with the new 400 and 600 range, whose prices start at just GBP 31,000, this tradition continues. No other entry-level lathe in this price bracket can match these new models for their quality, reliability and profit potential.
This price includes Fanuc 210i CNC control with Manual Guide, manual 3 jaw chuck (200mm), 8 station turret and tailstock with life centre.
Examples of the features that are atypical in this class of machine include the pivoting DMG SlimLinePanel with 15in TFT screen feature a top-of-the-range Fanuc or Siemens control with graphical user interface and 3D real-time simulation.
Rotational speeds are up to 4,000 rev/min with up to 24kW of drive power and 720Nm torque.
Not to be found on any other entry-level lathe is the 30 deg inclined four-track bed designed for optimal chip clearance and excellent accessibility.
High flexibility and productivity are assured thanks to a large working area and features such as a traversable steady rest and high-speed, 8-station turret.
As a result chucking components up to 55mm and shaft sections up to 1200mm in length can be machined in the shortest time.
The digital drive on the main spindle and dynamically stable linear guideways make a significant contribution to the high precision and excellent surface quality achievable on the new NEF universal lathes.
Manufacturing flexibility is assured by a traversable tailstock with hydraulic quill.
Other notable features are integrated safety systems and a low space requirement.
This fully enclosed machine series comes in a space green finish; metallic optional.
Monday, June 26, 2006
Heavy duty 2-axis, 50HP CNC lathe introduced
Shown for the first time among CNC lathes at MACH 2006 was a heavy duty 2-axis slant bed 50HP lathe has turning length of 1800mm and diameter of 700mm, and is for large shaft work.
Ward Hi-Tech used MACH 2006 to confirm their position as one of the leading privately owned CNC machine tool distributors in the UK. With more than 60 models available from a portfolio of principal partners that include Doosan Mecatec of Korea, Dah Lih of Taiwan and CME of Spain the company showed a total of 10 CNC machines - including three new models. The Doosan S700 heavy duty 2-axis slant bed lathe from South Korea has a turning length of 1800mm and is ideal for large shaft work.
The S700 accommodates chuck sizes up to 762mm diameter with a turning diameter of 700mm whilst its 50HP main motor and three step gear box delivers full power from 63 rev/min - making it ideally suited for heavy duty machining.
The lathe is equipped with rigid 12 station turret accommodating 32mm2 tooling and up to 60mm diameter boring bars.
The control is the powerful Fanuc 18iT system, which can drive the option of a driven tool turret and spindle C axis control.
The S700L will be demonstrated machining a typical large shaft component from the aerospace industry.
Also shown for the first time in the UK was a Doosan S400 slant bed 2-axis lathe.
Specification includes maximum turning diameter of 400mm, turning length of 716mm, chuck size of 12in (optional 15in dia.) with a bar capacity of 76.5mm (optional 99mm diameter).
The S400 has a 12 station drum type turret, accommodating a standard tool size of 25mm2 and boring bar of 50mm diameter.
it is equipped with a 'P' type 30HP wide power main motor and has spindle speeds of 35-3500 rev/min.
A standard feature of the S400 is the unique Doosan machine management (DMM) software built into the CNC system.
This provides the operator with a comprehensive 'on screen' menu of production information including machining time, production sort, tool life sister tool management, operational status report and machine maintenance guidance information.
* High power turning - the Doosan S550 LG is built with a 50HP main drive incorporating twin range ZF gear box ensuring full power is generated at 158 rev/min.
With chuck size of 15in or 18in diameter, turning length of 1130mm, 12 station turret and heavy duty tailstock, the S550 was shown machining a typical oil industry component from Nimonics demonstrating the suitability of this particular machine of tackling the most arduous of materials.
* Low cost, 2-axis turning - completing the line up of Doosan 2 axis turning machines at MACH was the ever popular S280N.
This best selling small CNC lathe is suited to a wide variety of applications across every industry sector and every size of user! The S280N specification features a maximum turning diameter of 280mm and turning length of 330mm, chuck size of 8in with bar capacity of 51mm dia.
Built with rigid box ways, 10 station turret and 15HP main drive motor, the S280N will be demonstrating its ability to 'hard turn' an aerospace component to a 'super precision' finish.
* vertical turning lathe - Doosan are one of the world's major manufacturers of vertical turning lathes (VTLs) producing VTLs for many well known automotive and aerospace companies in particular.
The Doosan V740 is one of the most popular size models in the VTL range and was displayed in single spindle format.
The machine has a maximum turning diameter of 740mm, cutting length of 760mm, 50HP main drive with twin range ZF gear box and 12 station turret and can accept chucks up to 24' diameter.
* Multi-axis CNC turning - wo examples from Doosan's multi axis turning range were featured during MACH.
The six axis sub-spindle S310SMLY includes Y-axis turret arrangement together with C-axis control of main and secondary spindle.
Other features include 12 station VDI style driven tool turret, maximum turning diameter of 311mm and machining length of 750mm, 10in chuck with 65mm bar capacity.
The machine will be shown producing a replica 'U' drill from bar utilising all six axes of control.
* Twin turret, multi-axis turning - the Doosan Z290SMY is an eight axis, twin turret, twin spindle turning centre.
Both main and sub spindles are fully synchronised and can be fitted with a combination of chuck or collect chuck.
Twin 12 station turrets can accommodate up to six driven tools in any combination whilst main and sub spindles both have full C-axis capability.
Maximum turning diameter is 290mm and machining length is 580mm with bar capacity of either 66mm or 77mm diameter.
For the MACH presentation the machine was coupled with a magazine bar loader and shown machining from bar a replica collet chuck that can be taken away and used as a desk paperweight.
Ward Hi-Tech used MACH 2006 to confirm their position as one of the leading privately owned CNC machine tool distributors in the UK. With more than 60 models available from a portfolio of principal partners that include Doosan Mecatec of Korea, Dah Lih of Taiwan and CME of Spain the company showed a total of 10 CNC machines - including three new models. The Doosan S700 heavy duty 2-axis slant bed lathe from South Korea has a turning length of 1800mm and is ideal for large shaft work.
The S700 accommodates chuck sizes up to 762mm diameter with a turning diameter of 700mm whilst its 50HP main motor and three step gear box delivers full power from 63 rev/min - making it ideally suited for heavy duty machining.
The lathe is equipped with rigid 12 station turret accommodating 32mm2 tooling and up to 60mm diameter boring bars.
The control is the powerful Fanuc 18iT system, which can drive the option of a driven tool turret and spindle C axis control.
The S700L will be demonstrated machining a typical large shaft component from the aerospace industry.
Also shown for the first time in the UK was a Doosan S400 slant bed 2-axis lathe.
Specification includes maximum turning diameter of 400mm, turning length of 716mm, chuck size of 12in (optional 15in dia.) with a bar capacity of 76.5mm (optional 99mm diameter).
The S400 has a 12 station drum type turret, accommodating a standard tool size of 25mm2 and boring bar of 50mm diameter.
it is equipped with a 'P' type 30HP wide power main motor and has spindle speeds of 35-3500 rev/min.
A standard feature of the S400 is the unique Doosan machine management (DMM) software built into the CNC system.
This provides the operator with a comprehensive 'on screen' menu of production information including machining time, production sort, tool life sister tool management, operational status report and machine maintenance guidance information.
* High power turning - the Doosan S550 LG is built with a 50HP main drive incorporating twin range ZF gear box ensuring full power is generated at 158 rev/min.
With chuck size of 15in or 18in diameter, turning length of 1130mm, 12 station turret and heavy duty tailstock, the S550 was shown machining a typical oil industry component from Nimonics demonstrating the suitability of this particular machine of tackling the most arduous of materials.
* Low cost, 2-axis turning - completing the line up of Doosan 2 axis turning machines at MACH was the ever popular S280N.
This best selling small CNC lathe is suited to a wide variety of applications across every industry sector and every size of user! The S280N specification features a maximum turning diameter of 280mm and turning length of 330mm, chuck size of 8in with bar capacity of 51mm dia.
Built with rigid box ways, 10 station turret and 15HP main drive motor, the S280N will be demonstrating its ability to 'hard turn' an aerospace component to a 'super precision' finish.
* vertical turning lathe - Doosan are one of the world's major manufacturers of vertical turning lathes (VTLs) producing VTLs for many well known automotive and aerospace companies in particular.
The Doosan V740 is one of the most popular size models in the VTL range and was displayed in single spindle format.
The machine has a maximum turning diameter of 740mm, cutting length of 760mm, 50HP main drive with twin range ZF gear box and 12 station turret and can accept chucks up to 24' diameter.
* Multi-axis CNC turning - wo examples from Doosan's multi axis turning range were featured during MACH.
The six axis sub-spindle S310SMLY includes Y-axis turret arrangement together with C-axis control of main and secondary spindle.
Other features include 12 station VDI style driven tool turret, maximum turning diameter of 311mm and machining length of 750mm, 10in chuck with 65mm bar capacity.
The machine will be shown producing a replica 'U' drill from bar utilising all six axes of control.
* Twin turret, multi-axis turning - the Doosan Z290SMY is an eight axis, twin turret, twin spindle turning centre.
Both main and sub spindles are fully synchronised and can be fitted with a combination of chuck or collect chuck.
Twin 12 station turrets can accommodate up to six driven tools in any combination whilst main and sub spindles both have full C-axis capability.
Maximum turning diameter is 290mm and machining length is 580mm with bar capacity of either 66mm or 77mm diameter.
For the MACH presentation the machine was coupled with a magazine bar loader and shown machining from bar a replica collet chuck that can be taken away and used as a desk paperweight.
Long bed CNC lathe has programmable tailstock
A long bed lathe - designed specifically to handle long parts, from oil field components to drive shafts to machinery rollers - comes equipped with a fully programmable hydraulic tailstock.
Long shafts and tubing pose unique challenges for turning centres, especially when deep-hole drilling and boring are involved. To meet those challenges Haas Automation introduces the new SL-40L Long-Bed lathe - a machine designed specifically to handle long parts, from oil field components to drive shafts to machinery rollers. The Haas SL-40L Long-Bed is an extended version of the company's shop-proven SL-40 turning centre that provides a maximum cutting length of 2032mm (nearly twice that of the standard SL-40) and a maximum cutting diameter of 647mm.
It also comes equipped with a fully programmable hydraulic tailstock.
In standard form, the machine features a 381mm chuck and an A2-8 spindle nose that provides a bar capacity of 101mm.
A 40HP (peak) vector dual-drive system combines with a high-torque gearbox to yield 1898Nm of spindle torque for heavy cutting, and provides speeds to 2,400 rev/min for finish work and high surface feedrates.
'On-the-fly' Y-delta switching provides the high torque and wide constant-horsepower band necessary for constant surface speed cuts.
To accommodate large-diameter tubing, a 'Big Bore' version of the SL-40L is also available.
This option upgrades the machine to an A2-11 spindle nose and features a 171mm through-bore (chuck, draw tube and hydraulic coupling are not included).
To support extra-long parts through the bore, a rear chuck provision is available that allows an air chuck to be mounted to the rear of the spindle.
An optional steady rest platform is also available to provide increased support for turning and boring long shafts.
Hydraulic power for the steady rest is provided by the lathe, and the gripper (not supplied) is activated automatically via M code.
Other options for the SL-40L Long-Bed lathe include live tooling, full C-axis, high-pressure coolant, a chip auger and a tool-presetter system.
A number of control options are also available, including expanded program memory, Ethernet interface, user-definable macros and Haas' conversational Visual Quick Code programming system.
Like all Haas machines, the SL-40L features the powerful and user-friendly Haas control.
Designed and built in-house, it is optimized specifically for Haas machines.
The Haas CNC accepts ISO standard G code and is compatible with all major CAM systems.
MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.
Haasl demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.
More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.
Long shafts and tubing pose unique challenges for turning centres, especially when deep-hole drilling and boring are involved. To meet those challenges Haas Automation introduces the new SL-40L Long-Bed lathe - a machine designed specifically to handle long parts, from oil field components to drive shafts to machinery rollers. The Haas SL-40L Long-Bed is an extended version of the company's shop-proven SL-40 turning centre that provides a maximum cutting length of 2032mm (nearly twice that of the standard SL-40) and a maximum cutting diameter of 647mm.
It also comes equipped with a fully programmable hydraulic tailstock.
In standard form, the machine features a 381mm chuck and an A2-8 spindle nose that provides a bar capacity of 101mm.
A 40HP (peak) vector dual-drive system combines with a high-torque gearbox to yield 1898Nm of spindle torque for heavy cutting, and provides speeds to 2,400 rev/min for finish work and high surface feedrates.
'On-the-fly' Y-delta switching provides the high torque and wide constant-horsepower band necessary for constant surface speed cuts.
To accommodate large-diameter tubing, a 'Big Bore' version of the SL-40L is also available.
This option upgrades the machine to an A2-11 spindle nose and features a 171mm through-bore (chuck, draw tube and hydraulic coupling are not included).
To support extra-long parts through the bore, a rear chuck provision is available that allows an air chuck to be mounted to the rear of the spindle.
An optional steady rest platform is also available to provide increased support for turning and boring long shafts.
Hydraulic power for the steady rest is provided by the lathe, and the gripper (not supplied) is activated automatically via M code.
Other options for the SL-40L Long-Bed lathe include live tooling, full C-axis, high-pressure coolant, a chip auger and a tool-presetter system.
A number of control options are also available, including expanded program memory, Ethernet interface, user-definable macros and Haas' conversational Visual Quick Code programming system.
Like all Haas machines, the SL-40L features the powerful and user-friendly Haas control.
Designed and built in-house, it is optimized specifically for Haas machines.
The Haas CNC accepts ISO standard G code and is compatible with all major CAM systems.
MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.
Haasl demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.
More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.
Compact CNC lathe has generous capacity
CNC lathe takes up only 2m x 1.5m of floor space, yet provides a generous 255mm turning diameter, 355mm turning length and a 415mm swing over the front apron.
Turning small parts on a large lathe usually is not the most efficient use of a company's assets, and actually may have an adverse effect on the bottom line. The SL-10 CNC lathe from Haas Automation provides an economical solution for small parts turning in a compact package that is loaded with full-size features. The SL-10 takes up only 2m x 1.5m of floor space, yet provides a generous 255mm turning diameter, 355mm turning length and a 415mm swing over the front apron.
This compact machine is a valuable addition to any shop needing a 'second-op' machine, or wanting to add a lathe where space is at a premium.
It is also the perfect lathe for start-up shops, or as a first step into CNC turning.
The SL-10 comes standard with a 160mm hydraulic chuck and a 10-position bolt-on tool turret.
A 5.6kW vector drive spindle provides speeds to 6,000 rev/min for high surface feedrates, and an A2-5 spindle nose accepts bar stock up to 45mm.
A host of high-productivity options, such as a tool presetter, parts catcher, automatic chip auger and tailstock, are available for the SL-10 to further boost productivity, and the Haas Servo Bar 300 intelligent bar feeder may be added for unattended operation.
MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.
Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.
More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.
Turning small parts on a large lathe usually is not the most efficient use of a company's assets, and actually may have an adverse effect on the bottom line. The SL-10 CNC lathe from Haas Automation provides an economical solution for small parts turning in a compact package that is loaded with full-size features. The SL-10 takes up only 2m x 1.5m of floor space, yet provides a generous 255mm turning diameter, 355mm turning length and a 415mm swing over the front apron.
This compact machine is a valuable addition to any shop needing a 'second-op' machine, or wanting to add a lathe where space is at a premium.
It is also the perfect lathe for start-up shops, or as a first step into CNC turning.
The SL-10 comes standard with a 160mm hydraulic chuck and a 10-position bolt-on tool turret.
A 5.6kW vector drive spindle provides speeds to 6,000 rev/min for high surface feedrates, and an A2-5 spindle nose accepts bar stock up to 45mm.
A host of high-productivity options, such as a tool presetter, parts catcher, automatic chip auger and tailstock, are available for the SL-10 to further boost productivity, and the Haas Servo Bar 300 intelligent bar feeder may be added for unattended operation.
MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.
Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.
More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.
Subscribe to:
Posts (Atom)
