Automated turning cells have enabled a UK contract machinist to turn the tables on its competitors in low wage economies by reducing labour cost differentials.
Much has been said of the threat to our subcontractors from China, India and some of the old Eastern bloc countries, but UK firms are fighting back. One contract machinist that has started to turn the tables on its competitors in low wage economies is Treworrick Engineering, Burgess Hill. During one of the worst recessions in UK manufacturing in recent years, the management had the courage to invest GBP 250,000 in two Daewoo automated turning cells from Mills Manufacturing - a bar-fed lathe and a gantry-loaded model - and is now reaping the rewards.
Said Treworrick director and co-owner, Clive Lambert, 'The advantage that low wage economies have over us is that we have to pay our machine operators far more, maybe 30 times as much.
But the labour cost differential becomes small if you minimise operator involvement by automating production.
'Then overseas subcontractors are at a disadvantage.
They cannot offer prices that are much lower, if at all, and need to ship container loads of parts every few months to keep transportation costs down.
This generates work-in-progress that is costly and inconvenient for the customer to stock.' His co-director, Richard Avery, contrasts this with the ability of subcontractors here to supply components and sub-assemblies just-in-time to UK manufacturers, directly to the production line if required.
Moreover the subcontractor is local and can be called in to discuss contracts face to face and troubleshoot any problems.
He commented, 'We have a longstanding customer in the hi-fi business that went straight to an Asian subcontractor for large volumes of a new component.
The company wanted to outsource 150,000 parts per year and did not think we could get close to the price they were quoted overseas, so they did not even approach us.
'However, due to a quality problem with the imported parts, they asked us to tide them over by running off 4,000 and to their surprise, our quote on this quantity based on using the Puma bar lathe was within one per cent of the price they were paying in Asia for the larger volumes.
So we have won all this business; and the customer does not have the hassle of stocking large quantities of parts or dealing at arms length with people over the other side of the world.
To be as competitive as this, however, subcontractors must invest in the latest automated equipment capable of minimally manned, one-hit production.
As soon as a component is handled and set up for subsequent operations, unit price soars, competitiveness suffers and margins vanish.
The two Daewoo lathes, each with live turret tooling and sub-spindle, are typical of the type of machine that is required.
The first, a Puma 230MS installed last Autumn (2002), has a Hydrafeed bar magazine and is capable of producing parts up to 65 mm diameter.
A second 230MS was installed this summer equipped with gantry load / unload to automate production of larger diameter work up to 200mm.
In addition, it can chuck manually-loaded components up to 230 mm, adding to its versatility.
To make room on the shop floor, Treworrick sold two conventional centre lathes of smaller capacity.
What used to be made from billet on these machines, sometimes requiring manual reversal for back end machining followed by further operations on a mill, is now made from bar on the first Puma lathe in one set up.
Likewise the second Puma has automated production of larger mill-turned parts and condensed multiple set-ups into one.
Significant labour savings have resulted and productivity has increased by between 30 and 40 per cent, due in part to being able to run the machines unmanned for two hours between the day and night shifts.
For example, a 25mm diameter by 80mm long EN8M steel part is now machined in 3.3 minutes on the Puma bar lathe, whereas it used to take 7 minutes floor-to-floor on a conventional bar lathe, manual chucker and milling machine.
Prismatic operations are fairly short at about 40 seconds for milling a hexagon and cross hole drilling.
As the combined efficiency of the previous machines was 80 per cent whereas the Puma is 95 per cent efficient, the overall saving on producing this part is nearly two thirds.
In another application, a 152mm diameter by 63mm long EN3A steel billet was formerly produced on two manually operated lathes and a mill in a floor-to-floor time of 11 minutes.
On the Puma gantry lathe, the same part is machined in one hit in 6 minutes and the cycle is expected to fall to below 5 minutes with fine tuning.
So the time saving on this part will be more than half.
Again, the non-turning proportion of the cycle is short at less than 20 per cent.
Clive Lambert took pleasure in pointing out that the component now undergoes its prismatic operations on the Puma lathe faster than it used to take the operator to blow the swarf off in the old lathe and refixture the part on the milling machine.
He therefore feels that he is getting this element of the cycle for free, especially as no operator intervention is necessary.
When it came to the investment in automated turning, both of the Treworrick directors decided that they did not want to plunge straight into the complexities of multi-turret or B-axis lathes.
They consider the single turrets on the Pumas are a better transition for a company such as theirs.
Two other shortlisted machines from other vendors suffered from either poor reputation for service or long turnover time for component reversal on the gantry machine, so Messrs Lambert and Avery opted to source both lathes from Mills.
Concluded Avery, 'We are working routinely to 10 microns total tolerance on the Pumas.
When customers visit and see the machines in action, they have no qualms about the quality of their components.
In this respect, the machines are a very good sales aid.
'Another benefit to us is that steel suppliers can see that we are turning over material quickly and so are happy to for us to hold inventory of bar and billet on consignment, for payment when we have used the material to make parts.
Cash flow is improved as a result.
Our suppliers never offered to do this when we were using the old centre lathes.'
Thursday, July 13, 2006
Holding a special form thread within microns in SS
There is a small threaded SS part made at CAM-C Engineering that would worry the life out of lathe setters and inspection unless the most suitable CNC lathe could be identified to do the job.
There is a small threaded stainless steel component produced at CAM-C Engineering that would worry the life out of lathe setters and inspection because of the 10 micron tolerance required over the outside diameter of the special form thread. So when it came to checking out how good the contending lathes for an order to make these parts were, CAM-C decided machining trials had to be the order of the day. As joint owner Mike Evans explains, Colchester put a Tornado A50 CNC lathe, fitted with the 'Lights-out' unmanned turning package, through its paces in the Heckmondwike factory test area and over a 24 hour period, the tolerance drift on the outside diameter of the thread never exceeded +/-2 microns.
Having then ordered a Colchester A50 Lights-out package for the Williams Town Rhondda factory from Colchester Sales Southern Technical Centre, RK International of Erith in Kent, Evans maintains even when they machine batches of up to 2,000 of these special screws: 'The machine never causes any need for concern.' Supplying tight tolerance precision engineered components to a number of top flight scientific and laboratory instrumentation manufacturers, CAM-C Engineering is often asked to perform what a normal subcontract operation would regard as the near impossible.
But, the company maintains, key to its capability is its investment in skill and machine tools.
Even with its reputation of high class precision component manufacture, South Wales-based CAM-C Engineering is more than happy to be known as a jobbing shop.
As Evans, explains: 'We are a jobbing shop, and work with just a few really good customers.
They may take some time to find but then we form a very close relationship.' CAM-C's well equipped machine shop in Williams Town, was set up by Mike Evans and his business partner, Jeff Geraci.
Collectively they have a wealth of experience, cultivated from very different engineering backgrounds but both are very familiar with difficult materials, precision and tight tolerances.
Jeff Geraci's experience was generated predominantly from a toolroom bias, making small quantities of intricate parts from hardened materials while Mike Evans was heavily involved with the volume production of very high tolerance components in often difficult materials.
Evans explains how the two of them normally quote for new jobs between them: 'I quote for the turning element, while Jeff focuses on any prismatic machining and then get together to determine how long the job will take.
Because we have such a close relationship with our customers we sometimes even try a job out at the quotation stage because we want to be sure that the customer will be satisfied and that we can complete the work on time and for the price.
We're not known as the cheapest, but our reputation is built upon a very thorough standard of work and timely delivery.' Although it began as a small order, the success of one of CAM-C's customers, in the production of gas analytical instrumentation, prompted the investment in the Colchester A50 CNC lathe.
Explains Evans: 'Initially this customer was struggling to find a supplier that could meet the level of quality on a stainless steel threaded component, especially because the quantity was very low.
Due to the fact we were willing to work at the job and able to achieve the tolerances required on an existing manual lathe, we then received a major influx of work which meant we were working up to 96 hours a week on this order.' This contract then led the two partners to seriously look at a CNC lathe which would be stable enough to maintain the tolerances required and was able to run consistently in a limited manned situation.
They decided to visit the MACH 2002 show at the NEC in Birmingham, and thoroughly investigated all of the turning centres that were within budget and it finally came down to a choice of just two machines.
Says Evans: 'I arranged to visit both suppliers to check out our stainless steel part being cut.
It was unbelievable that one of the demonstrations was such a complete washout, the machine could not catch the parts which are relatively short, so we could never confirm the accuracy on the last part cut bearing in mind it was an automatic cycle.' 'By complete contrast,' Evans reveals, 'the Colchester Tornado demonstrations initially held at RK International's showroom in Erith and later as a full trial at the Colchester factory in Heckmondwike was superb.
Although it is small, the component is fairly complex with a special high tolerance thread and three chamfers based around a critical undercut groove formed half-way down the part.' Evans continues: 'This groove is important because it acts as a guide and location pickup point for the automated test laboratory equipment that uses the finished assembly.
Also, the modified external thread has to be turned to provide a light, press fit into another part of the assembly.
The engineering solution to achieve the accurate generation of this thread form was where Colchester won the day.' The Colchester 'Lights-out' package comprises a fully integrated MBF 1000 bar feed system, programmable from the machine's Fanuc control, swarf conveyor, on-board Renishaw probing for size control and parts catcher.
The 12 station VDI turret machine also has work scheduling software and tool monitoring based on power sensing which can initiate sister tool replacement.
Another influencing factor in the purchasing decision was what CAM-C describe as the double backup available with both RK International and Colchester Sales which are both able to provide support.
Evans confirms: 'We have established a good relationship with RK and 99 per cent of the time any questions are answered directly on the telephone.
We did have a probing problem which caused the barfeed to reference.
Even though the Colchester service engineer quickly solved the problem, both Colchester and RK have made follow-up courtesy calls to ensure everything is still OK.' Most batch sizes produced by CAM-C Engineering seem to be around 10 parts.
Materials machined include stainless steel, brass, aluminium and a small quantity of titanium parts for a customer in the instrumentation industry.
As Evans outlines: 'Because we know our customers for lower volume parts we tend to group three months worth of production together and then link those parts to other batches we can produce out of the same size raw material.' Here, the 'Lights-out' machine package software has proven to be a boon because it has a scheduling system in the Fanuc control for up to 10 component types which allows the different parts to be nested in the same bar of material.
He adds: 'It suits us down to the ground, because a lot of our parts are similar in size and we can use similar tooling, to cover threads, holes and counterbores.' By clever planning, relatively low batch quantities of say 10 or 15 are easily turned into more economical batches of 100 or even 150 parts which are set during the day.
'Once we are confident of our tooling and programming, the machine is more than capable of running overnight.
We don't just use 'lights-out' turning, we live it, which gives us tremendous economies and machine utilisation,' insists Evans.
CAM-C purchased the A50 with a chuck to also enable billeted components to be produced.
The largest part turned so far is a 68mm diameter aluminium soil probe cap using the MBF 1000 integrated barfeed.
At the other end of the scale, although Colchester's recommended minimum bar size is 6mm, in order to prevent the push rod in the barfeed system fouling, the company has successfully run batches of parts below 5mm diameter.
It is also common to work close to the chuck to prevent any material deflection.
Indeed, by using special toolholders the tool is prevented from striking the chuck.
And, Evans maintains: 'The Colchester developed parts catcher works without any problems even on the smallest parts!'
There is a small threaded stainless steel component produced at CAM-C Engineering that would worry the life out of lathe setters and inspection because of the 10 micron tolerance required over the outside diameter of the special form thread. So when it came to checking out how good the contending lathes for an order to make these parts were, CAM-C decided machining trials had to be the order of the day. As joint owner Mike Evans explains, Colchester put a Tornado A50 CNC lathe, fitted with the 'Lights-out' unmanned turning package, through its paces in the Heckmondwike factory test area and over a 24 hour period, the tolerance drift on the outside diameter of the thread never exceeded +/-2 microns.
Having then ordered a Colchester A50 Lights-out package for the Williams Town Rhondda factory from Colchester Sales Southern Technical Centre, RK International of Erith in Kent, Evans maintains even when they machine batches of up to 2,000 of these special screws: 'The machine never causes any need for concern.' Supplying tight tolerance precision engineered components to a number of top flight scientific and laboratory instrumentation manufacturers, CAM-C Engineering is often asked to perform what a normal subcontract operation would regard as the near impossible.
But, the company maintains, key to its capability is its investment in skill and machine tools.
Even with its reputation of high class precision component manufacture, South Wales-based CAM-C Engineering is more than happy to be known as a jobbing shop.
As Evans, explains: 'We are a jobbing shop, and work with just a few really good customers.
They may take some time to find but then we form a very close relationship.' CAM-C's well equipped machine shop in Williams Town, was set up by Mike Evans and his business partner, Jeff Geraci.
Collectively they have a wealth of experience, cultivated from very different engineering backgrounds but both are very familiar with difficult materials, precision and tight tolerances.
Jeff Geraci's experience was generated predominantly from a toolroom bias, making small quantities of intricate parts from hardened materials while Mike Evans was heavily involved with the volume production of very high tolerance components in often difficult materials.
Evans explains how the two of them normally quote for new jobs between them: 'I quote for the turning element, while Jeff focuses on any prismatic machining and then get together to determine how long the job will take.
Because we have such a close relationship with our customers we sometimes even try a job out at the quotation stage because we want to be sure that the customer will be satisfied and that we can complete the work on time and for the price.
We're not known as the cheapest, but our reputation is built upon a very thorough standard of work and timely delivery.' Although it began as a small order, the success of one of CAM-C's customers, in the production of gas analytical instrumentation, prompted the investment in the Colchester A50 CNC lathe.
Explains Evans: 'Initially this customer was struggling to find a supplier that could meet the level of quality on a stainless steel threaded component, especially because the quantity was very low.
Due to the fact we were willing to work at the job and able to achieve the tolerances required on an existing manual lathe, we then received a major influx of work which meant we were working up to 96 hours a week on this order.' This contract then led the two partners to seriously look at a CNC lathe which would be stable enough to maintain the tolerances required and was able to run consistently in a limited manned situation.
They decided to visit the MACH 2002 show at the NEC in Birmingham, and thoroughly investigated all of the turning centres that were within budget and it finally came down to a choice of just two machines.
Says Evans: 'I arranged to visit both suppliers to check out our stainless steel part being cut.
It was unbelievable that one of the demonstrations was such a complete washout, the machine could not catch the parts which are relatively short, so we could never confirm the accuracy on the last part cut bearing in mind it was an automatic cycle.' 'By complete contrast,' Evans reveals, 'the Colchester Tornado demonstrations initially held at RK International's showroom in Erith and later as a full trial at the Colchester factory in Heckmondwike was superb.
Although it is small, the component is fairly complex with a special high tolerance thread and three chamfers based around a critical undercut groove formed half-way down the part.' Evans continues: 'This groove is important because it acts as a guide and location pickup point for the automated test laboratory equipment that uses the finished assembly.
Also, the modified external thread has to be turned to provide a light, press fit into another part of the assembly.
The engineering solution to achieve the accurate generation of this thread form was where Colchester won the day.' The Colchester 'Lights-out' package comprises a fully integrated MBF 1000 bar feed system, programmable from the machine's Fanuc control, swarf conveyor, on-board Renishaw probing for size control and parts catcher.
The 12 station VDI turret machine also has work scheduling software and tool monitoring based on power sensing which can initiate sister tool replacement.
Another influencing factor in the purchasing decision was what CAM-C describe as the double backup available with both RK International and Colchester Sales which are both able to provide support.
Evans confirms: 'We have established a good relationship with RK and 99 per cent of the time any questions are answered directly on the telephone.
We did have a probing problem which caused the barfeed to reference.
Even though the Colchester service engineer quickly solved the problem, both Colchester and RK have made follow-up courtesy calls to ensure everything is still OK.' Most batch sizes produced by CAM-C Engineering seem to be around 10 parts.
Materials machined include stainless steel, brass, aluminium and a small quantity of titanium parts for a customer in the instrumentation industry.
As Evans outlines: 'Because we know our customers for lower volume parts we tend to group three months worth of production together and then link those parts to other batches we can produce out of the same size raw material.' Here, the 'Lights-out' machine package software has proven to be a boon because it has a scheduling system in the Fanuc control for up to 10 component types which allows the different parts to be nested in the same bar of material.
He adds: 'It suits us down to the ground, because a lot of our parts are similar in size and we can use similar tooling, to cover threads, holes and counterbores.' By clever planning, relatively low batch quantities of say 10 or 15 are easily turned into more economical batches of 100 or even 150 parts which are set during the day.
'Once we are confident of our tooling and programming, the machine is more than capable of running overnight.
We don't just use 'lights-out' turning, we live it, which gives us tremendous economies and machine utilisation,' insists Evans.
CAM-C purchased the A50 with a chuck to also enable billeted components to be produced.
The largest part turned so far is a 68mm diameter aluminium soil probe cap using the MBF 1000 integrated barfeed.
At the other end of the scale, although Colchester's recommended minimum bar size is 6mm, in order to prevent the push rod in the barfeed system fouling, the company has successfully run batches of parts below 5mm diameter.
It is also common to work close to the chuck to prevent any material deflection.
Indeed, by using special toolholders the tool is prevented from striking the chuck.
And, Evans maintains: 'The Colchester developed parts catcher works without any problems even on the smallest parts!'
Where standard CNC lathe is the best choice
In some types of small batch work, component geometry and non-turning content determines that a standard CNC lathe is more suitable than a mill-turn centre says an antennas manufacturer.
Stratford-upon-Avon based Precision Antennas is experiencing a boom! Since the start of 2002 the company has expanded its workforce by almost half to 192 people and is adding to its factory capacity. In line with this expansion, the company has recently installed two of the latest Colchester Tornado 220 lathes, bringing the number of Tornado machines in the factory to four. Precision Antennas is privately owned with over 50 years' experience in the development and manufacture of antennas and associated support structures.
Its installed manufacturing capabilities support the fabrication of dish-form antennae up to 6.4 metres in diameter, and single piece and hand-spun antennae up to 4.5 metres.
Manufacturing manager, Alan Brooks explains the philosophy that has created such success: 'Our ability to design, develop and build virtually all our key components in-house not only guarantees quality and performance but it also means we can respond very quickly to customer's needs.
Our customer base is largely drawn from the mobile telephone industry, OEM radio systems manufacturers, global communications service providers and the defence sector.' The company's products are exported worldwide, either directly and indirectly, and due to the nature of the business, almost all manufacturing output is made to contract.
While batches can sometimes reach 250, quantities tend to be nearer 10 or 20 parts.
Machining facilities at the factory now range right up to full five-axis milling capability.
For two-axis turning, the company has focused on chucking versions of the Colchester Tornado which originated with the installation of a Tornado 100, followed by a larger capacity 210 machine.
Precision Antennas was then one of the first companies in the UK to install the latest Tornado 220 following its launch in 2001 and quickly followed with a second machine as production demands grew.
As Brooks maintains: 'When you look at the value for money aspect of the Colchester product we don't know of any other lathe on the market that can match it.' He follows on to outline that although some of the turned parts require subsequent drilling and milling operations, because the batch quantities are so small, breaking the turning from machining of the other features is the most cost-effective method and a Tornado is quicker to set up than a mill/turn lathe.
Brooks describes how the Tornado machines can maintain tolerances without any problems and the operators and setters particularly like the improved ergonomics and working area of the latest 220 compared to the 210.
He describes how having four machines out of the same stable means operators can easily move from machine to machine without thinking, and the company has excellent backward/forward capability with CNC programs giving considerable tooling flexibility.
'When you bear in mind the Tornado 220 was some 20 per cent less expensive than the previous 210 model, it is certainly a lot of lathe for the money.
An additional factor in the decision to stay with the Colchester product is the good after-sales support we have received.' The original Tornado 100 has a bar puller which enables bar lengths to be machined, but by far and away most operations across the four machines are based on castings and sawn billets.
Component diameters span 25mm to 350mm and cycle times vary between 90 seconds and 15 minutes.
'Operations mainly comprise outside turning, face grooving, boring and internal tapers and grooves but we also machine quite a lot of parabolic curves which require interpolation,' he says.
Coupled with program delivery by DNC, most changeovers take around 30 minutes which includes chuck jaws.
But as Alan Brooks describes, the improved ergonomics of the latest 220 machines make life much easier.
Among the improvements in the machines between the 210 and 220 is the Colchester patented base redesign which introduced 'Duo-stable' construction incorporating an engineered concrete polymer base fill.
To this foundation Colchester added heavier and larger ways which contribute to improved static and dynamic stiffness, and the whole machine has higher thermal stability.
These basic improvements enabled higher power 22kW motors and drives to be included in the specification with much improved spindle design, faster axis motions and turret indexing.
And, with redesign and positioning of the hydraulic tank at the front of the machine and coolant tank at the opposite end, maintenance and swarf removal is easier and operational benefits through grease lubrication in favour of total loss oil, gives improved coolant consistency and cutting tool and coolant life.
The versatility of the machines is further enhanced by the way in which Precision Antennas operates them.
Some components are programmed with stops in the cycle which allow the operator to turn or relocate the part in the chuck jaws before re-starting the cycle.
In addition as three of the machines are arranged in a 'U' formation this enables more flexible operation as a cell.
'The aim is to always get a finished turned component from the machine with one operator visit, and failing that, to progress work through the turning section as quickly as possible,' concludes Brooks.
Stratford-upon-Avon based Precision Antennas is experiencing a boom! Since the start of 2002 the company has expanded its workforce by almost half to 192 people and is adding to its factory capacity. In line with this expansion, the company has recently installed two of the latest Colchester Tornado 220 lathes, bringing the number of Tornado machines in the factory to four. Precision Antennas is privately owned with over 50 years' experience in the development and manufacture of antennas and associated support structures.
Its installed manufacturing capabilities support the fabrication of dish-form antennae up to 6.4 metres in diameter, and single piece and hand-spun antennae up to 4.5 metres.
Manufacturing manager, Alan Brooks explains the philosophy that has created such success: 'Our ability to design, develop and build virtually all our key components in-house not only guarantees quality and performance but it also means we can respond very quickly to customer's needs.
Our customer base is largely drawn from the mobile telephone industry, OEM radio systems manufacturers, global communications service providers and the defence sector.' The company's products are exported worldwide, either directly and indirectly, and due to the nature of the business, almost all manufacturing output is made to contract.
While batches can sometimes reach 250, quantities tend to be nearer 10 or 20 parts.
Machining facilities at the factory now range right up to full five-axis milling capability.
For two-axis turning, the company has focused on chucking versions of the Colchester Tornado which originated with the installation of a Tornado 100, followed by a larger capacity 210 machine.
Precision Antennas was then one of the first companies in the UK to install the latest Tornado 220 following its launch in 2001 and quickly followed with a second machine as production demands grew.
As Brooks maintains: 'When you look at the value for money aspect of the Colchester product we don't know of any other lathe on the market that can match it.' He follows on to outline that although some of the turned parts require subsequent drilling and milling operations, because the batch quantities are so small, breaking the turning from machining of the other features is the most cost-effective method and a Tornado is quicker to set up than a mill/turn lathe.
Brooks describes how the Tornado machines can maintain tolerances without any problems and the operators and setters particularly like the improved ergonomics and working area of the latest 220 compared to the 210.
He describes how having four machines out of the same stable means operators can easily move from machine to machine without thinking, and the company has excellent backward/forward capability with CNC programs giving considerable tooling flexibility.
'When you bear in mind the Tornado 220 was some 20 per cent less expensive than the previous 210 model, it is certainly a lot of lathe for the money.
An additional factor in the decision to stay with the Colchester product is the good after-sales support we have received.' The original Tornado 100 has a bar puller which enables bar lengths to be machined, but by far and away most operations across the four machines are based on castings and sawn billets.
Component diameters span 25mm to 350mm and cycle times vary between 90 seconds and 15 minutes.
'Operations mainly comprise outside turning, face grooving, boring and internal tapers and grooves but we also machine quite a lot of parabolic curves which require interpolation,' he says.
Coupled with program delivery by DNC, most changeovers take around 30 minutes which includes chuck jaws.
But as Alan Brooks describes, the improved ergonomics of the latest 220 machines make life much easier.
Among the improvements in the machines between the 210 and 220 is the Colchester patented base redesign which introduced 'Duo-stable' construction incorporating an engineered concrete polymer base fill.
To this foundation Colchester added heavier and larger ways which contribute to improved static and dynamic stiffness, and the whole machine has higher thermal stability.
These basic improvements enabled higher power 22kW motors and drives to be included in the specification with much improved spindle design, faster axis motions and turret indexing.
And, with redesign and positioning of the hydraulic tank at the front of the machine and coolant tank at the opposite end, maintenance and swarf removal is easier and operational benefits through grease lubrication in favour of total loss oil, gives improved coolant consistency and cutting tool and coolant life.
The versatility of the machines is further enhanced by the way in which Precision Antennas operates them.
Some components are programmed with stops in the cycle which allow the operator to turn or relocate the part in the chuck jaws before re-starting the cycle.
In addition as three of the machines are arranged in a 'U' formation this enables more flexible operation as a cell.
'The aim is to always get a finished turned component from the machine with one operator visit, and failing that, to progress work through the turning section as quickly as possible,' concludes Brooks.
Tuesday, July 11, 2006
Service company moves into CNC machining too
Having begun in business supplying machinery ancillaries and spares, a service company found it was subcontracting out much machining, until it decided to set up its own CNC facilities.
If it's a fast response that's needed, look no further than Replacement and Maintenance Supplies of Alfreton, Derbyshire where, according to Andy Douthwaite and John Whelan, 'we don1t know what to expect from the time we come in to the time we go home'. But whatever it is, one thing is certain: 'When a production line is down because of, say, a broken shaft, the customer wants an immediate response'. Before setting up the business in 1987, both directors were involved with the specialist bearing side of Unipart and this explains why, initially, Replacement and Maintenance Supplies was wholly focused on supplying bearings and related power transmission products such as gears, seals, pulleys, bushes and belting.
Today, however, it also offers a comprehensive machining service tailored specifically to repair work.
Although the company has an off-line programming capability, most of the programming takes place on the machine.
That's why a Proturn VL 425 manual/CNC lathe supplied and installed several months ago by XYZ Machine Tools has become a firm favourite, and has now been joined by a XYZ SM 4000 manual/CNC bed mill.
Both machines are equipped with the innovative Prototrak control that makes switching between manual and CNC operation on the same set-up straightforward and fast.
'The software is brilliant and it's ideal for one-offs,' says Andy Douthwaite, 'Before we set up the machine shop three years ago, we were placing quite of a lot of work with local engineering companies and I noticed they were using XYZ machines.
Having followed their example, I am enjoying the benefits because the new machines are quick to set-up and this business is all about speed.' The 10HP/7.5kW Proturn VL 425 high-speed gap bed lathe already installed is available with either 1.25m or 2m between centres, and features an 80mm spindle bore and spindle speeds from 15 to 2500 rpm.
Constant surface speed is also standard, courtesy of the VL control that provides custom-designed screens to make every operation - whether a clearance cycle, profiling or drilling routines, or standard and custom threads - follow in a logical and clear sequence.
Unlike other CNCs, all the operator is required to do is to define the part geometry and stock dimensions.
From these inputs the toolpath, including all roughing passes and the speeds and feeds, is generated.
The emphasis on breakdown work at Replacement and Maintenance Supplies dictates a high level of individual skill and equipment that is both versatile and easy to use.
'Quantities are usually one to five-offs and most of the time we are working without drawings,' says Andy Douthwaite.
'So we only recruit highly skilled people who can deal with a job from start to finish.
This means liasing directly with the customer, measuring up on site where necessary, using every aspect of our machining facilities, including MIG/TIG welding, inspecting the end result and, above all, knowing that, once installed, the replacement part will have the customer up and running in the shortest possible time.' Since speed is of the essence, the company tends to restrict its activities to relatively local customers and refuses for the most part to quote for production-type work that could restrict the flexibility of its machining operation.
But, says Douthwaite, 'we are always re-inventing ourselves and this brings us into contact with new customers.
If, for example, we are asked to machine a replacement impeller, we develop a new skill and we then look to where we can offer that particular expertise.
If it's a fast response that's needed, look no further than Replacement and Maintenance Supplies of Alfreton, Derbyshire where, according to Andy Douthwaite and John Whelan, 'we don1t know what to expect from the time we come in to the time we go home'. But whatever it is, one thing is certain: 'When a production line is down because of, say, a broken shaft, the customer wants an immediate response'. Before setting up the business in 1987, both directors were involved with the specialist bearing side of Unipart and this explains why, initially, Replacement and Maintenance Supplies was wholly focused on supplying bearings and related power transmission products such as gears, seals, pulleys, bushes and belting.
Today, however, it also offers a comprehensive machining service tailored specifically to repair work.
Although the company has an off-line programming capability, most of the programming takes place on the machine.
That's why a Proturn VL 425 manual/CNC lathe supplied and installed several months ago by XYZ Machine Tools has become a firm favourite, and has now been joined by a XYZ SM 4000 manual/CNC bed mill.
Both machines are equipped with the innovative Prototrak control that makes switching between manual and CNC operation on the same set-up straightforward and fast.
'The software is brilliant and it's ideal for one-offs,' says Andy Douthwaite, 'Before we set up the machine shop three years ago, we were placing quite of a lot of work with local engineering companies and I noticed they were using XYZ machines.
Having followed their example, I am enjoying the benefits because the new machines are quick to set-up and this business is all about speed.' The 10HP/7.5kW Proturn VL 425 high-speed gap bed lathe already installed is available with either 1.25m or 2m between centres, and features an 80mm spindle bore and spindle speeds from 15 to 2500 rpm.
Constant surface speed is also standard, courtesy of the VL control that provides custom-designed screens to make every operation - whether a clearance cycle, profiling or drilling routines, or standard and custom threads - follow in a logical and clear sequence.
Unlike other CNCs, all the operator is required to do is to define the part geometry and stock dimensions.
From these inputs the toolpath, including all roughing passes and the speeds and feeds, is generated.
The emphasis on breakdown work at Replacement and Maintenance Supplies dictates a high level of individual skill and equipment that is both versatile and easy to use.
'Quantities are usually one to five-offs and most of the time we are working without drawings,' says Andy Douthwaite.
'So we only recruit highly skilled people who can deal with a job from start to finish.
This means liasing directly with the customer, measuring up on site where necessary, using every aspect of our machining facilities, including MIG/TIG welding, inspecting the end result and, above all, knowing that, once installed, the replacement part will have the customer up and running in the shortest possible time.' Since speed is of the essence, the company tends to restrict its activities to relatively local customers and refuses for the most part to quote for production-type work that could restrict the flexibility of its machining operation.
But, says Douthwaite, 'we are always re-inventing ourselves and this brings us into contact with new customers.
If, for example, we are asked to machine a replacement impeller, we develop a new skill and we then look to where we can offer that particular expertise.
Competitive CNC lathes are highly user-friendly
Working very closely with European machine tool builders, a revitalised machine tool company will show competitively priced CNC lathes at MACH 2004, with the latest user-friendly, touch-screen CNCs.
Ajax Machinery's new owner will be presenting a revitalised company and introducing new ranges of high quality, cost-effective products at MACH. These new Ajax machine tools include European-manufactured manual CNC and production lathes, universal CNC bed milling machines, vertical machining centres and vertical band saws. According to Managing Director, William Savin: 'We have reawakened the giant that was Ajax and are bringing it back to the forefront.
Since I acquired the company we have set about raising the quality of the products and services we offer to a new high.
' We have been working very closely with European machine tool builders to develop product ranges that are manufactured under contract for us to our exacting specifications.
The engineering experience of these companies is second to none and we are not afraid to acknowledge them - we want them to be proud to be manufacturing for us,' he says.
One of the fruits of this product development programme is a new manual CNC lathe, the Ajax Apollo QT.
The machines feature Fanuc's QuickTurn control as well as Fanuc drives and motors.
At prices ranging from GBP 12,950 for a 335mm swing lathe with 750mm between centres to GBP 28,950 for a 620mm swing 155mm spindle bore machine with 3m between centres, the range offers the benefits of simple user-friendly CNC for the same price as many manual lathes.
'We see the Apollo QT as a manual lathe with CNC assistance,' says William.
'The touch screen control is very simple to use.
A manual turner can get straight on the machine and use it.
If he wants to he can operate it without engaging the control, but why wind a handle when the CNC will do the job more quickly?
This is aimed at being a replacement for manual machines.' Wherever possible Ajax now offers the choice of European manufactured machinery at a price comparable to Far Eastern machines from other suppliers.
In a number of areas, such as turret mills, it complements its Ajax range of European machines with even more cost effective Taiwanese alternatives.
The company has recently relocated to purpose-built premises in Lymington that give it the capacity to support its continuing expansion.
Ajax Machinery's new owner will be presenting a revitalised company and introducing new ranges of high quality, cost-effective products at MACH. These new Ajax machine tools include European-manufactured manual CNC and production lathes, universal CNC bed milling machines, vertical machining centres and vertical band saws. According to Managing Director, William Savin: 'We have reawakened the giant that was Ajax and are bringing it back to the forefront.
Since I acquired the company we have set about raising the quality of the products and services we offer to a new high.
' We have been working very closely with European machine tool builders to develop product ranges that are manufactured under contract for us to our exacting specifications.
The engineering experience of these companies is second to none and we are not afraid to acknowledge them - we want them to be proud to be manufacturing for us,' he says.
One of the fruits of this product development programme is a new manual CNC lathe, the Ajax Apollo QT.
The machines feature Fanuc's QuickTurn control as well as Fanuc drives and motors.
At prices ranging from GBP 12,950 for a 335mm swing lathe with 750mm between centres to GBP 28,950 for a 620mm swing 155mm spindle bore machine with 3m between centres, the range offers the benefits of simple user-friendly CNC for the same price as many manual lathes.
'We see the Apollo QT as a manual lathe with CNC assistance,' says William.
'The touch screen control is very simple to use.
A manual turner can get straight on the machine and use it.
If he wants to he can operate it without engaging the control, but why wind a handle when the CNC will do the job more quickly?
This is aimed at being a replacement for manual machines.' Wherever possible Ajax now offers the choice of European manufactured machinery at a price comparable to Far Eastern machines from other suppliers.
In a number of areas, such as turret mills, it complements its Ajax range of European machines with even more cost effective Taiwanese alternatives.
The company has recently relocated to purpose-built premises in Lymington that give it the capacity to support its continuing expansion.
CNC lathe cuts extrusion die machining by 70%
Following the investment in a CNC slant bed chucking lathe a leading producer of extrusion dies for plastics and rubber insulation has cut extrusion die machining up to 70 per cent.
The company has also adopted hard turning of materials up to 45 HRC and reduced grinding requirements by a third. Aspin Engineering has since expanded its business into general sub contract machining.
Says managing director Dr Anton Aspin: 'We decided to buy the Tornado 220 CNC lathe following a visit to the Colchester Sales Technical Centre in Heckmondwike.
Originally selected from a shortlist of three turning machines, it was the performance, accuracy and overall value for money that were the major advantages we determined.' He follows on to outline: 'I was particularly impressed by the construction with its wide slideways and polymer concrete filled base which gives a high level of stability.
In my view, stability is an important prerequisite in a machine for holding the tight tolerances which we regularly have to work to on a wide range of precision extrusion dies and various other turning projects.' Dr Aspin's comments on the construction are confirmed following the Tornado's installation in the company's 4,500 (square feet) factory unit on the Moss Lane Trading Estate in Greater Manchester in April.
Cycle times on H13 and P20 tool steel extrusion tooling have been cut in half and 316 stainless steel mixer part machining times have been slashed by almost 70 per cent.
But there have been even further benefits as Dr Aspin explained: 'We have been able to eliminate around a third of our cylindrical grinding work as the Tornado can turn extrusion points and dies consistently to an almost unbelievable accuracy of + 5 microns.
What's more, we've also been able to comfortably machine a range of toughened materials up to 45 HRC, using standard tooling.' Aspin Engineering has found the GE Fanuc B series 21-i controlled Tornado 220 is quick and simple to program.
In fact, the company reckons that it is also able to produce single parts economically on the lathe as it is so easy to generate part programs.
However, batch sizes of between five and 10 are deemed more realistic.
It is the ability of the machine to effectively handle larger volumes of work that is seen as important for expansion of the Aspin Engineering business and has enabled additional savings to be created by the company.
For example, when Aspin received a large order for extrusion parts late last year, it had to spend around GBP 10,000 over a three month period on subcontracting much of the turning due to capacity problems in achieving the scheduled delivery dates.
As Dr Aspin added: 'This really motivated us to look at being self-sufficient and buy a new CNC chucking lathe.' When Dr Aspin discusses the purchase he maintains the lathe's all-round performance and accuracy is directly attributable to its patented 'Duo-Stable' construction which provides a highly stable, true 60 (Degrees) slant bed turning platform.
The base foundation with its engineered polymer concrete fill, strategic reinforcement and integral cast iron bed, reflects an increase in machine weight of some 50 per cent which is coupled with a corresponding 25 per cent improvement in damping.
'This is where the 'performance and accuracy factors' are created and the machine easily copes with the 22 kW spindle power making the larger 250 mm diameter chuck capacity and tailstock options that we ordered meet our planned requirements.' Other advanced technical features of the machine include: larger headstock and a stiffer, five-bearing spindle design; wider, lower and heavier slideways; and improved thermal characteristics - which collectively provide the stability factor required for really high performance machining.
Set-up in 1984 and employing 14 people, Aspin Engineering's work load is now split 20 per cent between producing wire and cable extrusion dies, 40 per cent on general subcontract work and other products and 40 per cent on added-value small assemblies.
The company has CNC machine tools of which two are vertical machining centres, a Colchester Electronic lathe and two thread grinding machines.
Its production of dies for insulating cables ranges from telecommunications work requirements of 0.5mm diameter right up to 152mm diameter for power cables.
Extrusion points and dies range in size from 20mm to 250mm diameter while stainless steel rotors and stators are also produced in diameters up to 200mm.
The company's own Cavity Transfer Miser (CTM) system product, which significantly improves the mixing/blending performance of an extruder, is produced in sizes from 20 mm to 600 mm diameter.
There's no doubt that the Tornado 220 has made a big impression since its arrival at the company's Whitefield works earlier this year.
As Dr Aspin concluded: 'The Tornado has extended our capacity, widened our scope of operations, eliminated certain grinding operations and, allowed us to look at work we could never have economically handled before.
The lathe can also turn to an accuracy of between five and 10 microns and it regularly does this without any special attention.'
The company has also adopted hard turning of materials up to 45 HRC and reduced grinding requirements by a third. Aspin Engineering has since expanded its business into general sub contract machining.
Says managing director Dr Anton Aspin: 'We decided to buy the Tornado 220 CNC lathe following a visit to the Colchester Sales Technical Centre in Heckmondwike.
Originally selected from a shortlist of three turning machines, it was the performance, accuracy and overall value for money that were the major advantages we determined.' He follows on to outline: 'I was particularly impressed by the construction with its wide slideways and polymer concrete filled base which gives a high level of stability.
In my view, stability is an important prerequisite in a machine for holding the tight tolerances which we regularly have to work to on a wide range of precision extrusion dies and various other turning projects.' Dr Aspin's comments on the construction are confirmed following the Tornado's installation in the company's 4,500 (square feet) factory unit on the Moss Lane Trading Estate in Greater Manchester in April.
Cycle times on H13 and P20 tool steel extrusion tooling have been cut in half and 316 stainless steel mixer part machining times have been slashed by almost 70 per cent.
But there have been even further benefits as Dr Aspin explained: 'We have been able to eliminate around a third of our cylindrical grinding work as the Tornado can turn extrusion points and dies consistently to an almost unbelievable accuracy of + 5 microns.
What's more, we've also been able to comfortably machine a range of toughened materials up to 45 HRC, using standard tooling.' Aspin Engineering has found the GE Fanuc B series 21-i controlled Tornado 220 is quick and simple to program.
In fact, the company reckons that it is also able to produce single parts economically on the lathe as it is so easy to generate part programs.
However, batch sizes of between five and 10 are deemed more realistic.
It is the ability of the machine to effectively handle larger volumes of work that is seen as important for expansion of the Aspin Engineering business and has enabled additional savings to be created by the company.
For example, when Aspin received a large order for extrusion parts late last year, it had to spend around GBP 10,000 over a three month period on subcontracting much of the turning due to capacity problems in achieving the scheduled delivery dates.
As Dr Aspin added: 'This really motivated us to look at being self-sufficient and buy a new CNC chucking lathe.' When Dr Aspin discusses the purchase he maintains the lathe's all-round performance and accuracy is directly attributable to its patented 'Duo-Stable' construction which provides a highly stable, true 60 (Degrees) slant bed turning platform.
The base foundation with its engineered polymer concrete fill, strategic reinforcement and integral cast iron bed, reflects an increase in machine weight of some 50 per cent which is coupled with a corresponding 25 per cent improvement in damping.
'This is where the 'performance and accuracy factors' are created and the machine easily copes with the 22 kW spindle power making the larger 250 mm diameter chuck capacity and tailstock options that we ordered meet our planned requirements.' Other advanced technical features of the machine include: larger headstock and a stiffer, five-bearing spindle design; wider, lower and heavier slideways; and improved thermal characteristics - which collectively provide the stability factor required for really high performance machining.
Set-up in 1984 and employing 14 people, Aspin Engineering's work load is now split 20 per cent between producing wire and cable extrusion dies, 40 per cent on general subcontract work and other products and 40 per cent on added-value small assemblies.
The company has CNC machine tools of which two are vertical machining centres, a Colchester Electronic lathe and two thread grinding machines.
Its production of dies for insulating cables ranges from telecommunications work requirements of 0.5mm diameter right up to 152mm diameter for power cables.
Extrusion points and dies range in size from 20mm to 250mm diameter while stainless steel rotors and stators are also produced in diameters up to 200mm.
The company's own Cavity Transfer Miser (CTM) system product, which significantly improves the mixing/blending performance of an extruder, is produced in sizes from 20 mm to 600 mm diameter.
There's no doubt that the Tornado 220 has made a big impression since its arrival at the company's Whitefield works earlier this year.
As Dr Aspin concluded: 'The Tornado has extended our capacity, widened our scope of operations, eliminated certain grinding operations and, allowed us to look at work we could never have economically handled before.
The lathe can also turn to an accuracy of between five and 10 microns and it regularly does this without any special attention.'
Sunday, July 09, 2006
Versatile CNC lathes, turning centres shown
Among 10 machining centres, CNC lathes and a VTL to be shown at MACH 2004, will be a large spindle bore CNC lathe, turning centres and a CNC VTL with a 17kW driven tool facility.
With a total of 10 machines being displayed - including three new models from Kia (the 1 m plus capacity VX500 vertical machining centre), Toshulin (the cost-competitive SKL12 vertical boring and turning machine) and Soraluce (the high-performance SP-8000 travelling column, fixed-bed mill, which is also likely to be the biggest machine at the show), Ward CNC's 500m2 display in Hall 4, the largest stand at MACH, will certainly emphasise that both 'big and small machines are beautiful'. With a variety of the machines either under power or cutting metal, the Ward CNC display will also include representatives of the company's Union (boring and milling) and Hankook (turning) ranges, so clearly the Sheffield-based machine tool specialist will be presenting something for everyone at the NEC. Included in the 11 machine tools on show, and being demonstrated, are the following CNC lathes and vertical turning lathe (VTL): * Toshulin SKL12 VTL.
a.
Three Kia turning centres - SKT21LMSB with driven tools and sub-spindle, SKT15LM universal with driven tools, and the SKT300 heavy-duty with geared head and solid slideways.
* Hankook 9NC large spindle bore CNC lathe with front and rear chucks and 4000mm between centres.
Visitors to the stand will be spoilt for turning centre choice, with three models on view.
Complete with a C axis, live tooling, sub-spindle and a 65mm spindle bore, the Super Kia Turn 21LMSB is a machine that Ward CNC managing director Simon Whitworth describes as 'world beating' for maximising value-for-money productivity on bar work up to 65mm.
The main 15/11kW spindle motor produces 25 to 4,000 revs/min, while the 3.7/2.2kW sub-spindle reaches 30 to 6,000 revs/min.
The 12-station bi-directional turret has a driven tool speed range of 20 to 4,000 revs/min generated by a 3.7/2.2kW motor.
With an X axis (cross) travel of 220mm and a Z axis (longitudinal) travel of 550mm, the machine has a maximum swing over the bed of 550mm and a distance between centres of 530mm.
Rapid traverse rates are 36m/min.
The Super Kia Turn SKT300 has a maximum turning diameter of 560mm, a maximum turning length of 720mm and a 90mm diameter bar capacity/305mm diameter chuck.
Travels in X and Z axes are 355mm and 750mm and the spindle provides 3,000 revs/min.
Feed rates 20m/min and 24m/min in X and Z, respectively.
With a 12-tool turret and two-stepped geared headstock designed for high-torque, heavy cutting, and programmable tailstock, the Fanuc-controlled SKT300 is designed to minimise non-cutting times while consistently producing parts to 3.5 micron accuracies (in brass, for example).
Completing the Kia display will be the Super Turn 15LM universal three-axis turning centre with driven tools and C axis, having a maximum swing of 550mm and turning diameter of 255mm.
Distance between centres on this 43mm bar capacity machine is 530mm.
Spindle speeds reach 6,000 revs/min, and rapid traverse rate in both the 220mm X and 550mm Z axes is 36m/min.
New from Toshulin is the SKL12 VTL, which can turn and face workpiece diameters up to 1700mm, and has a Z axis capacity of 1200mm and a ram stroke of 1000mm.
With a 1250mm diameter table having a speed range up to 500 revs/min, and an up to 10 revs/min C axis, the 17kW machine's driven tool spindle has an infinitely variable speed range up to 3,000 revs/min, complemented by working travels and rapid traverse rates of 1-4000mm/min and 3000mm/min, respectively.
Typifying the high quality of build and cost-and-performance specification available from Hankook, the Protec 9NC lathe is based on a double-walled and ribbed one-piece meehanite cast iron bed with induction hardened and ground precision slideways for maximum stability and accuracy.
The large spindle bore (up to 440mm) 9NC has a 950mm swing over the bed, 630mm over the carriage and 4000mm between centres.
With Fanuc CNC, the machine boasts spindle speeds of 2 to 1,000/3 to 440 revs/min.
Marposs Mida Laser 105 laser toolsetting and an E86 radio transmission spindle probe will also be evident on the Ward CNC stand.
With a total of 10 machines being displayed - including three new models from Kia (the 1 m plus capacity VX500 vertical machining centre), Toshulin (the cost-competitive SKL12 vertical boring and turning machine) and Soraluce (the high-performance SP-8000 travelling column, fixed-bed mill, which is also likely to be the biggest machine at the show), Ward CNC's 500m2 display in Hall 4, the largest stand at MACH, will certainly emphasise that both 'big and small machines are beautiful'. With a variety of the machines either under power or cutting metal, the Ward CNC display will also include representatives of the company's Union (boring and milling) and Hankook (turning) ranges, so clearly the Sheffield-based machine tool specialist will be presenting something for everyone at the NEC. Included in the 11 machine tools on show, and being demonstrated, are the following CNC lathes and vertical turning lathe (VTL): * Toshulin SKL12 VTL.
a.
Three Kia turning centres - SKT21LMSB with driven tools and sub-spindle, SKT15LM universal with driven tools, and the SKT300 heavy-duty with geared head and solid slideways.
* Hankook 9NC large spindle bore CNC lathe with front and rear chucks and 4000mm between centres.
Visitors to the stand will be spoilt for turning centre choice, with three models on view.
Complete with a C axis, live tooling, sub-spindle and a 65mm spindle bore, the Super Kia Turn 21LMSB is a machine that Ward CNC managing director Simon Whitworth describes as 'world beating' for maximising value-for-money productivity on bar work up to 65mm.
The main 15/11kW spindle motor produces 25 to 4,000 revs/min, while the 3.7/2.2kW sub-spindle reaches 30 to 6,000 revs/min.
The 12-station bi-directional turret has a driven tool speed range of 20 to 4,000 revs/min generated by a 3.7/2.2kW motor.
With an X axis (cross) travel of 220mm and a Z axis (longitudinal) travel of 550mm, the machine has a maximum swing over the bed of 550mm and a distance between centres of 530mm.
Rapid traverse rates are 36m/min.
The Super Kia Turn SKT300 has a maximum turning diameter of 560mm, a maximum turning length of 720mm and a 90mm diameter bar capacity/305mm diameter chuck.
Travels in X and Z axes are 355mm and 750mm and the spindle provides 3,000 revs/min.
Feed rates 20m/min and 24m/min in X and Z, respectively.
With a 12-tool turret and two-stepped geared headstock designed for high-torque, heavy cutting, and programmable tailstock, the Fanuc-controlled SKT300 is designed to minimise non-cutting times while consistently producing parts to 3.5 micron accuracies (in brass, for example).
Completing the Kia display will be the Super Turn 15LM universal three-axis turning centre with driven tools and C axis, having a maximum swing of 550mm and turning diameter of 255mm.
Distance between centres on this 43mm bar capacity machine is 530mm.
Spindle speeds reach 6,000 revs/min, and rapid traverse rate in both the 220mm X and 550mm Z axes is 36m/min.
New from Toshulin is the SKL12 VTL, which can turn and face workpiece diameters up to 1700mm, and has a Z axis capacity of 1200mm and a ram stroke of 1000mm.
With a 1250mm diameter table having a speed range up to 500 revs/min, and an up to 10 revs/min C axis, the 17kW machine's driven tool spindle has an infinitely variable speed range up to 3,000 revs/min, complemented by working travels and rapid traverse rates of 1-4000mm/min and 3000mm/min, respectively.
Typifying the high quality of build and cost-and-performance specification available from Hankook, the Protec 9NC lathe is based on a double-walled and ribbed one-piece meehanite cast iron bed with induction hardened and ground precision slideways for maximum stability and accuracy.
The large spindle bore (up to 440mm) 9NC has a 950mm swing over the bed, 630mm over the carriage and 4000mm between centres.
With Fanuc CNC, the machine boasts spindle speeds of 2 to 1,000/3 to 440 revs/min.
Marposs Mida Laser 105 laser toolsetting and an E86 radio transmission spindle probe will also be evident on the Ward CNC stand.
Linear motor drives expand CNC lathes' versatility
Claimed to far outperform any traditional single spindle cam machines in both flexibility and profitability, a linear motor drive CNC automatic makes simultaneous use of several tools.
Claimed to far outperform any traditional single spindle cam machines in both flexibility and profitability, a linear motor drive CNC automatic makes simultaneous use of several tools. For those who were unable to attend the last EMO, DMG is staging a British re-run, complete with several machines never before demonstrated publicly in the UK. In total, eleven machines will feature showing a wide range of machining solutions and four of those are brand new.
The star performer for turning is undoubtedly the new Sprint 32 linear, aptly named as it far outperforms any traditional single spindle cam machines in both flexibility and profitability.
One of the key features of this new CNC automatic turning machine is its motor spindle and the linear arrangement of the tool holders, which allow the simultaneous use of several tools.
These features, combined with the unique configuration of up to 8 axes, make it possible to process turned parts, inexpensively and at reduced cycle times.
The next universal turning newcomer is the CTX410, one of the latest additions to the CTX 10-Series whose hallmark is low capital cost; a CTX210 model with Fanuc control will also feature on the stand.
Competitive price is achieved through efficient production and assembly methods.
In addition to the standard configuration, the design may be specified with fixed or driven tools.
The use of high-tech components such as the integrated spindle motor and fast servo-turret ensure up to 25% idle time reduction resulting in greater productivity and cost efficiency.
With the introduction of the new GMX 200 linear, DMG extends it turn-mill capabilities up to 560mm diameter, making this product line the most comprehensive for complete 6-sided machining with linear technology.
A linear drive, compound slides with a Y- and B-axis and the highly dynamic turning and milling spindle with 100Nm and a maximum 12,000 rpm are just some of the features that make this machine both a high-end lathe and a high-tech machining centre.
Speed and angle-synchronous workpiece transfers as well as integrated spindle motors provide the shortest cycle times, both for the counter spindle and the tail stock versions.
Thanks to linear drive technology, the CTX 320 linear universal lathe has been rewarding several UK companies with significant productivity increases and at MACH its abilities will be demonstrated on 65mm bar.
DMG's twin spindle range is to be represented by the Twin 65.
The large frame size of this lathe has created space for a CNC-controlled B-axis in the area of the upper turret.
In combination with the Y-axis and driven tools, it is therefore able to machine slanted bores, planes and even complicated milling contours.
Claimed to far outperform any traditional single spindle cam machines in both flexibility and profitability, a linear motor drive CNC automatic makes simultaneous use of several tools. For those who were unable to attend the last EMO, DMG is staging a British re-run, complete with several machines never before demonstrated publicly in the UK. In total, eleven machines will feature showing a wide range of machining solutions and four of those are brand new.
The star performer for turning is undoubtedly the new Sprint 32 linear, aptly named as it far outperforms any traditional single spindle cam machines in both flexibility and profitability.
One of the key features of this new CNC automatic turning machine is its motor spindle and the linear arrangement of the tool holders, which allow the simultaneous use of several tools.
These features, combined with the unique configuration of up to 8 axes, make it possible to process turned parts, inexpensively and at reduced cycle times.
The next universal turning newcomer is the CTX410, one of the latest additions to the CTX 10-Series whose hallmark is low capital cost; a CTX210 model with Fanuc control will also feature on the stand.
Competitive price is achieved through efficient production and assembly methods.
In addition to the standard configuration, the design may be specified with fixed or driven tools.
The use of high-tech components such as the integrated spindle motor and fast servo-turret ensure up to 25% idle time reduction resulting in greater productivity and cost efficiency.
With the introduction of the new GMX 200 linear, DMG extends it turn-mill capabilities up to 560mm diameter, making this product line the most comprehensive for complete 6-sided machining with linear technology.
A linear drive, compound slides with a Y- and B-axis and the highly dynamic turning and milling spindle with 100Nm and a maximum 12,000 rpm are just some of the features that make this machine both a high-end lathe and a high-tech machining centre.
Speed and angle-synchronous workpiece transfers as well as integrated spindle motors provide the shortest cycle times, both for the counter spindle and the tail stock versions.
Thanks to linear drive technology, the CTX 320 linear universal lathe has been rewarding several UK companies with significant productivity increases and at MACH its abilities will be demonstrated on 65mm bar.
DMG's twin spindle range is to be represented by the Twin 65.
The large frame size of this lathe has created space for a CNC-controlled B-axis in the area of the upper turret.
In combination with the Y-axis and driven tools, it is therefore able to machine slanted bores, planes and even complicated milling contours.
Cost-effective production lathes programmed easily
A range of strong, reliable and cost-effective production lathes feature a CNC that is is straightforward to program by operator interface or direct on line programming.
Ajax has launched two new ranges of European-manufactured lathes, the manual/CNC Apollo QT series and the Ajax Apollo PD production lathes. The Ajax Apollo PD series is built around robust and reliable European-built lathes combined with the latest Fanuc 21i CNC control, giving a range of strong, reliable and cost-effective production lathes. The powerful Fanuc 21i control is straightforward to program by operator interface or direct on line programming, the operator interface gives advanced machining, tool management and calculation of complex shapes and functions.
Ajax are currently offering the option of a full production package, this includes hollow spindle hydraulic chuck, hydraulic tailstock and an 8 station automatic turret.
Special introductory prices for this equipment range from GBP 3650 to GBP 4950, depending on the size of machine.
With the above package coupled to a lathe swinging 400mm, and 1000mm between centres, with Fanuc 21i control, Fanuc drives and motors, the complete production package is less than GBP 29,000.
The Ajax Apollo QT manual/CNC lathes feature Fanuc's QuickTurn control and Fanuc drives and motors.
The range of Ajax QTs has been developed as a replacement for the conventional centre lathe.
An experienced lathe operator would quickly adapt and start machining immediately when combining his knowledge with the Fanuc QuickTurn technology.
The Fanuc QuickTurn control provides and easy-to-understand, operator-friendly interface, leading the operator through standard turning functions using the touch screen display.
Manual operation is by two electronic hand wheels, with varying feed rates and using the display as a simple 2-axis DRO.
Complex shapes and operations can be programmed using a selection of canned cycles that are accessed through the touch screen display.
Up to 15 operations can be stored in the control.
These operations cover: rough turning and facing cycles; thread cutting cycles, including taper threads; radius and chamfer cycles; grooving cycles and drilling cycles.
Prices range from GBP 12,950 for a machine of 335mm swing, 750mm between centres, to GBP 28,950 for a machine of 620mm swing, 155mm diameter spindle bore and 3000mm between centres.
The range offers the benefit of a lathe with and operator-friendly control for the same price as a fully-equipped conventional centre lathe.
Ajax has launched two new ranges of European-manufactured lathes, the manual/CNC Apollo QT series and the Ajax Apollo PD production lathes. The Ajax Apollo PD series is built around robust and reliable European-built lathes combined with the latest Fanuc 21i CNC control, giving a range of strong, reliable and cost-effective production lathes. The powerful Fanuc 21i control is straightforward to program by operator interface or direct on line programming, the operator interface gives advanced machining, tool management and calculation of complex shapes and functions.
Ajax are currently offering the option of a full production package, this includes hollow spindle hydraulic chuck, hydraulic tailstock and an 8 station automatic turret.
Special introductory prices for this equipment range from GBP 3650 to GBP 4950, depending on the size of machine.
With the above package coupled to a lathe swinging 400mm, and 1000mm between centres, with Fanuc 21i control, Fanuc drives and motors, the complete production package is less than GBP 29,000.
The Ajax Apollo QT manual/CNC lathes feature Fanuc's QuickTurn control and Fanuc drives and motors.
The range of Ajax QTs has been developed as a replacement for the conventional centre lathe.
An experienced lathe operator would quickly adapt and start machining immediately when combining his knowledge with the Fanuc QuickTurn technology.
The Fanuc QuickTurn control provides and easy-to-understand, operator-friendly interface, leading the operator through standard turning functions using the touch screen display.
Manual operation is by two electronic hand wheels, with varying feed rates and using the display as a simple 2-axis DRO.
Complex shapes and operations can be programmed using a selection of canned cycles that are accessed through the touch screen display.
Up to 15 operations can be stored in the control.
These operations cover: rough turning and facing cycles; thread cutting cycles, including taper threads; radius and chamfer cycles; grooving cycles and drilling cycles.
Prices range from GBP 12,950 for a machine of 335mm swing, 750mm between centres, to GBP 28,950 for a machine of 620mm swing, 155mm diameter spindle bore and 3000mm between centres.
The range offers the benefit of a lathe with and operator-friendly control for the same price as a fully-equipped conventional centre lathe.
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