Hotchkiss evaluated the Colchester Combi 6000 from the Colchestersales (UK) Southern Technical Centre at RK International in Erith, Kent, to represent the best return on investment.
The Hotchkiss family has been associated with engineering since at least 1799 when John, a Royal Navy Lieutenant invented a mechanism for lifting heavy weights and ships anchors. Indeed, it was a modification of his development that is said to have helped the British fleet to outgun the opposition at the Battle of Trafalgar because it enabled cannon balls to be transported far quicker and easier to the gundecks. Today, the family owned Hotchkiss Group, located at West Kingsdown, a stones throw from the Brands Hatch race circuit in Kent, is a specialist heavy machine workshop and general engineering business.
The Group is split into two operations.
John Hotchkiss Engineering named after the current managing director Bill Hotchkiss' father, is still well known for developing, producing, re-engineering and refurbishing rolls largely for the paper industry but also applies its diverse skills to the cable making sector, mining, shipping, car breaking and food producers.
The heavy duty operations of the business would not normally be expected in the Kent countryside - perhaps more at home in the Midlands or North East, but the skills in the business are very specialised for the 23 people operation.
A further 40 are also employed 20 miles away in Strood at the Group's contract engineering operation, Westwell Developments, which undertakes refurbishment, rebuilding and resiting of plant and machinery.
These projects range from fragmentisers used in scrap metal reclamation weighting up to 40 tonnes each, to pump transmissions for a wide range of industries.
The nature of the business is obvious when viewing the West Kingsdown machine shop where craneage can manoeuvre rolls and fabrications weighing up to 60 tonnes.
Its largest lathe has 2.6 m swing by 11.2 m between centres, two other lathes have 12 m and 8.5 m between centre dimensions but by clever siting of beds these machines can form a single unit, with a massive 20 m between centres capacity.
A 17 m long roll grinder has a 1.6 m swing by 10 m between centres and a CNC mill a 6 m by 8 m table.
It was, however, the demand for higher precision and productivity on smaller shaft and chucking work for refurbishing and general turning that recently set Bill Hotchkiss's workshop team to look across the market for a CNC lathe to replace an ageing centre lathe.
They eventually evaluated the Colchester Combi 6000 from the Colchestersales (UK) Southern Technical Centre at RK International in Erith, Kent, to represent the best return on investment.
In particular, it was the machines credentials as a combination lathe able to perform one-off tasks, have very easy to use programming assist and its ability to faithfully reproduce further components when required under automatic cycle that scored highly in the evaluation.
Says Bill Hotchkiss: 'We are engineers and are constantly involved with quite complicated mechanisms and structures.
While we tend to 'engineer' solutions on a large scale, we require high levels of flexibility in our machining because we never know what is going to come through the door.
Our equipment has to be real work horses so top of the agenda for any lathe we were going to install was real fitness for purpose.' The Hotchkiss family definitely has engineering in the genes.
In 1872 Benjamin Berkley Hotchkiss, credited by Bill as probably the most famous of them all, invented the revolving-barrel machine gun and a magazine rifle that became widely used in British, French and American Military.
Later he turned his talents to designing engines, particularly the internal combustion engine, founded the company that produced the famous Hotchkiss car in 1903 and is now sought after by enthusiasts around the world.
In 1930 Donald Hotchkiss, a ship's architect invented the coned propeller used by tugboats for manoeuvring ships in harbour and Bill's father John, who started the current company in 1938 with just £75, invented the portable rotary lathe in the 50s.
His invention was a breakthrough because it enabled in-situ machining and repair work to be carried out on bearing journals on large rolls in paper mills for instance, saving the time and expense of major stripdowns.
He also developed an in-situ keyway cutter able to cut keys in shafts up to 75 cm long by 10 cm wide and another invention of his was the HB static-spindle bearing cartridge that totally revolutionised roll installation and maintenance.
His development enabled the bearing to be changed in-situ, without the roll having to be removed from the machine.
Other inventions include a single bearing 12 metre hydraulically driven floor level rotary turntable capable of coiling some 600 tonnes of submarine power and optical fibre cables without twist during manufacture.
Components machined today on the Combi 6000 are to far higher tolerance and surface finish than could be produced before and quite often repair and reclamation demands a lot of turning skill which, operator Dave Plant maintains, the Manual Guidei software on the Combi is extremely useful in support of what he needs to do.
He describes an often and classic case that would take ages to get the component running true and parallel when, say, a journal diameter has to be remachined.
'I set it true in a four-jaw chuck and then quickly program in a slight taper to compensate for parallelism rather than have to mess around jacking the tailstock.
This type of flexibility has allowed us to reduce a job that could take around three days to within a shift or at worst, a day and a half.' Much of the work is shaft based, these can be up to 300 mm diameter by 1,500 mm long and involving multi step diameters and the finish turning of journal diameters.
Tolerances tend to be 0.012 mm for bearing diameters and surface finish straight from the machine are often required to be within 0.8 and 1.6 um RA.
Says Dave Plant: 'Most of our shaft work is on pretty tough material such as EN24T and EN42 and due to the type of work a lot of threads are machined.
Here I find the screw cutting macros on the Combi are really helpful as we have to machine both metric and imperial and these can be between 50 mm and 300 mm diameter by 100 mm long.
We also have to produce the occasional taper thread.' He also makes use of the simulation on difficult parts and has found the rigidity of the Combi ideal for roughing out with 3 mm depth of cut on the shaft work.
'It will easily cut faster but you need to take into account insert life.
We are not a production shop,' he says, 'most parts are just single items but we do use the CNC for repeat cycles when we can have batches of up to six parts.' As Bill Hotchkiss maintains: 'We needed a machine that would give us a good quality turn.
It was the guys in the workshop that made the decision and they are the ones who make the installation a success.
When we look at the overall package from Colchestersales and the price that was paid, we feel we are getting a very good return on our investment.'
Friday, June 23, 2006
'Entry level' CNC lathe has wide application
A low cost, 'entry level' 15kW main spindle turning machine has been designed on the basis of machining a wide range of components within the smallest possible amount of space.
The new low cost, entry level, XYZ Mini Turn 190 turning centre has been designed on the basis of machining a wide range of components within the smallest possible amount of space. Although it is the smallest model in XYZ Machine Tools' range of turning centres, the 15kW, 4000 rev/min XYZ Mini Turn 190 is capable of a 200mm maximum turned diameter and has a maximum swing of 400mm. It also features a 56mm spindle bore, with a 42mm drawtube capacity, to accommodate oversize bar.
Axis travels are 155mm (X) and 510mm (Z), with rapid traverse rates of 12 and 14m/min, respectively.
Distance between centres is 500mm and the XYZ Mini Turn 190 is equipped with an 8-station turret that holds 40mm diameter boring bars and turning tools with a 20mm by 20mm shank.
Occupying a space-saving 2700mm (W) by 1670mm (D) by 1800mm (H), the XYZ Mini Turn 190 is equipped as standard with a 200mm three-jaw hydraulic chuck, flood coolant and Siemens 810D conversational Shopturn CNC.
Rigidity and vibration absorption is guaranteed by the Meehanite cast iron construction, with the machine weighing in at 4200kg, and auto lubricated hardened and ground slideways ensure smooth axes travel, minimum wear and a high quality surface finish for the machined component.
Offering a host of canned cycles, the Siemens 810D Shopturn control makes shopfloor programming fast and simple, involving the minimum of keystrokes and the maximum reassurance to the less experienced operator.
The new low cost, entry level, XYZ Mini Turn 190 turning centre has been designed on the basis of machining a wide range of components within the smallest possible amount of space. Although it is the smallest model in XYZ Machine Tools' range of turning centres, the 15kW, 4000 rev/min XYZ Mini Turn 190 is capable of a 200mm maximum turned diameter and has a maximum swing of 400mm. It also features a 56mm spindle bore, with a 42mm drawtube capacity, to accommodate oversize bar.
Axis travels are 155mm (X) and 510mm (Z), with rapid traverse rates of 12 and 14m/min, respectively.
Distance between centres is 500mm and the XYZ Mini Turn 190 is equipped with an 8-station turret that holds 40mm diameter boring bars and turning tools with a 20mm by 20mm shank.
Occupying a space-saving 2700mm (W) by 1670mm (D) by 1800mm (H), the XYZ Mini Turn 190 is equipped as standard with a 200mm three-jaw hydraulic chuck, flood coolant and Siemens 810D conversational Shopturn CNC.
Rigidity and vibration absorption is guaranteed by the Meehanite cast iron construction, with the machine weighing in at 4200kg, and auto lubricated hardened and ground slideways ensure smooth axes travel, minimum wear and a high quality surface finish for the machined component.
Offering a host of canned cycles, the Siemens 810D Shopturn control makes shopfloor programming fast and simple, involving the minimum of keystrokes and the maximum reassurance to the less experienced operator.
Turning centre machines wide range of materials
With its 12-tool VDI turret allied to a 254mm chuck and 550mm swing, a 22.5kW, turning centre is ideally suited to a range of parts in ferrous and NF metals and many engineering plastics.
Larry Houghton knows what it must be like to fly at speeds up to 44 miles/h for up to 120 km attached to little more than a parachute and a giant fan. He also knows what it is like to crack a few ribs when landing, although this painful experience has in no way diminished his enthusiasm for the exciting new sport of paramotoring. His involvement with what he describes as the closest you can get to having a James Bond jetpack strapped to your back stems from his day job running Lamb Engineering, a small sub-contracting company located in South Newton, west of Salisbury.
One of his customers is Parajet, the Mere, Wiltshire, UK-based company set up a couple of years ago by 26 years-old Giles Cardozo, inventor, engineer and pioneer of paramotoring.
Demand for the 24 hp Parajet Volution that, believe it or not, features cruise control as standard, is such that Parajet now claims to be gearing up to produce thousands of these powered paragliders each year.
This, in part, explains Larry Houghton's decision to install a XYZ 250 TC turning centre alongside several other machine tools supplied by XYZ Machine Tools.
Lamb Engineering's first XYZ purchase was a manual lathe equipped with digital readout, which was followed by two turret mills, the second a manual/CNC machine equipped with the easy-to-use ProtoTRAK control, and then two vertical machining centres.
The XYZ 250 TC is the company's most recent purchase, a decision that reflects both an increasing amount of turning work and its previous reliance on a rather elderly CNC lathe.
With its 12-tool VDI turret allied to a 254mm chuck and 550mm swing, the 22.5kW, 3500 rev/min XYZ 250 TC is ideally suited to the range of parts machined by Lamb Engineering in ferrous and non-ferrous metals and many types of engineering plastics.
Between them the XYZ CNC machines produce a range of components for the Parajet Volution 170 cc motor and, says Larry Houghton, have performed well, adding that the training and after-sales service he has received from the Burlescombe, Devon machine tool supplier cannot be faulted.
His ISO 9002 accredited company, which began in 1987 and moved to its present 2500ft2 site six years ago, is unusual in that as well as precision machining it is also equipped to produce electronic assemblies as well as for welding and fabrication work.
In addition to machining precision components for the Parajet Volution engine, Lamb Engineering also manufactures the guard that encases the carbon fibre blades.
This versatility, combined with the company's in-house design expertise and its willingness to manufacture anything from prototypes to finished products, has resulted in a diverse customer base that provides Houghton with the engineering challenges he thrives on.
Although only five people are involved, including Houghton's business partner, Andy Strange, Lamb Engineering has come a long way from its 'odd job' beginnings to what today he describes as a business whose expertise in solving customers' problems: 'Is what makes us stand out from companies offering only conventional manufacturing and engineering services.' Houghton said: 'We have established a solid reputation for finding the quickest route to a solution appropriate to the application, and our business has grown through recommendations passed on by customers who already trust us to respond quickly with a competitive price, generated either from a quick sketch or a fully fledged design.
Over the years we reckon to have saved customers such as Parajet substantial sums of money by coming up with less expensive alternatives to their original design and manufacturing requirements.
Larry Houghton knows what it must be like to fly at speeds up to 44 miles/h for up to 120 km attached to little more than a parachute and a giant fan. He also knows what it is like to crack a few ribs when landing, although this painful experience has in no way diminished his enthusiasm for the exciting new sport of paramotoring. His involvement with what he describes as the closest you can get to having a James Bond jetpack strapped to your back stems from his day job running Lamb Engineering, a small sub-contracting company located in South Newton, west of Salisbury.
One of his customers is Parajet, the Mere, Wiltshire, UK-based company set up a couple of years ago by 26 years-old Giles Cardozo, inventor, engineer and pioneer of paramotoring.
Demand for the 24 hp Parajet Volution that, believe it or not, features cruise control as standard, is such that Parajet now claims to be gearing up to produce thousands of these powered paragliders each year.
This, in part, explains Larry Houghton's decision to install a XYZ 250 TC turning centre alongside several other machine tools supplied by XYZ Machine Tools.
Lamb Engineering's first XYZ purchase was a manual lathe equipped with digital readout, which was followed by two turret mills, the second a manual/CNC machine equipped with the easy-to-use ProtoTRAK control, and then two vertical machining centres.
The XYZ 250 TC is the company's most recent purchase, a decision that reflects both an increasing amount of turning work and its previous reliance on a rather elderly CNC lathe.
With its 12-tool VDI turret allied to a 254mm chuck and 550mm swing, the 22.5kW, 3500 rev/min XYZ 250 TC is ideally suited to the range of parts machined by Lamb Engineering in ferrous and non-ferrous metals and many types of engineering plastics.
Between them the XYZ CNC machines produce a range of components for the Parajet Volution 170 cc motor and, says Larry Houghton, have performed well, adding that the training and after-sales service he has received from the Burlescombe, Devon machine tool supplier cannot be faulted.
His ISO 9002 accredited company, which began in 1987 and moved to its present 2500ft2 site six years ago, is unusual in that as well as precision machining it is also equipped to produce electronic assemblies as well as for welding and fabrication work.
In addition to machining precision components for the Parajet Volution engine, Lamb Engineering also manufactures the guard that encases the carbon fibre blades.
This versatility, combined with the company's in-house design expertise and its willingness to manufacture anything from prototypes to finished products, has resulted in a diverse customer base that provides Houghton with the engineering challenges he thrives on.
Although only five people are involved, including Houghton's business partner, Andy Strange, Lamb Engineering has come a long way from its 'odd job' beginnings to what today he describes as a business whose expertise in solving customers' problems: 'Is what makes us stand out from companies offering only conventional manufacturing and engineering services.' Houghton said: 'We have established a solid reputation for finding the quickest route to a solution appropriate to the application, and our business has grown through recommendations passed on by customers who already trust us to respond quickly with a competitive price, generated either from a quick sketch or a fully fledged design.
Over the years we reckon to have saved customers such as Parajet substantial sums of money by coming up with less expensive alternatives to their original design and manufacturing requirements.
Friday, June 16, 2006
Solid base on which to turn one-offs
Colchester has combined the stability of a solid base and an advanced control and software package into the Combi K-Series CNC lathe for one-off components or batch production.
By combining the stability of a solid base, a 30 deg cast iron slant bed and one of the most advanced control and software packages available for one-off components or batch production, Colchester Lathe's Combi K-Series of CNC turning machines redefine the advantages of simplicity of operation, power and accuracy in a turning machine. Developed specifically for the workshop, toolroom, jobshop and lower quantity batchwork, Combi is now available in K2, K3 and K4 versions which depict capacity and power. In addition across the range, a wide array of options allows the user to specify a machine for general or specific requirements.
For instance, a choice is available of chucks, steadies and tailstock that runs on independent ways, quick-change tool posts or 8-station auto-indexing Duplomatic turrets.
The Combi K2 has a swing over bed of 400mm, X-axis travel of 220mm and up to 1,270mm between centres while the mid-range K3 increases swing to 460mm, X-axis to 290mm and introduces a choice of between centres dimensions of 1016 mm, 1524 mm and 2032 mm.
For the K4 its larger 554mm swing is complemented with X-axis and between centres the same as K3 but with an additional capacity for between centres of 3168mm.
With machining capacity of this order, stability is critical to achieve high performance.
Combi's engineered concrete fill for the base creates an equilibrium within the structure giving the turning process the basic advantage of consistency even when using higher feed rates and greater depth of cut.
In addition, improved surface finish and consistent tolerance machining from part to part can be readily achieved.
Mounted on the base is a cast iron bed giving a 30 deg slant bed configuration which has been patented by Colchester based on its accessibility for operation.
It also creates a low centre of gravity and new levels of freedom for swarf evacuation from the cutting zone.
The machine saddle and cross-slide assembly uses a triple bearing configuration utilising two linear rails at the front and one at the rear which eliminates any tendency for the saddle to 'crab' and the ballscrew drive is mounted in board of the rails.
This design ensures accuracy and stability are maintained under cut and accommodates the 98 per cent increase in Z-axis thrust available with the new K-Series over the previous machine design.
The guide rail also bridges the bed gap via a further patented design.
The single piece cast headstock fitted with Gamet precision taper roller bearings uses a two-stage ZF clutch/pulley arrangement between the 11kW, 15kW and 22kW GE Fanuc Alpha main spindle motors fitted respectively to the K2, K3 and K4 variants.
The Colchester design of spindle drive gives a 20:1 constant power band ratio for high torque turning at low revolutions.
This is best illustrated with the K4 which can provide a massive 1,900Nm of torque at just 112 revs/min.
In keeping with the target users of Combi, Colchester Lathe has developed the Fanuc 210-TA digital control and Windows 95TM format software around Visual Basic.
The on-screen, icon-driven CAM-based system gives a real time virtual tool display while having full compatibility with other Fanuc G-code based programs.
The open-CNC control software can be programmed by six different methods from a simple digital read-out, through on-screen CAM and electronic handwheel teach and repeat, cut and paste, traditional G-code and by direct numerical control download.
The 960 capacity tool library also utilises icon identification and visual recognition of the tool shape and carries the respective geometric tool data with feed and speed information which can be overridden by the operator.
Rescaling of the tool active zone helps detail viewing of the operation which is a critical function when working on intricate or internal features and a wide selection of macros speed the operator through his setting task.
With new design of slide-aside guarding, access is excellent while large viewing windows coupled with high integrity interlocks and a sliding operator panel means the Colchester Combi introduces new levels of ergonomic operation.
By combining the stability of a solid base, a 30 deg cast iron slant bed and one of the most advanced control and software packages available for one-off components or batch production, Colchester Lathe's Combi K-Series of CNC turning machines redefine the advantages of simplicity of operation, power and accuracy in a turning machine. Developed specifically for the workshop, toolroom, jobshop and lower quantity batchwork, Combi is now available in K2, K3 and K4 versions which depict capacity and power. In addition across the range, a wide array of options allows the user to specify a machine for general or specific requirements.
For instance, a choice is available of chucks, steadies and tailstock that runs on independent ways, quick-change tool posts or 8-station auto-indexing Duplomatic turrets.
The Combi K2 has a swing over bed of 400mm, X-axis travel of 220mm and up to 1,270mm between centres while the mid-range K3 increases swing to 460mm, X-axis to 290mm and introduces a choice of between centres dimensions of 1016 mm, 1524 mm and 2032 mm.
For the K4 its larger 554mm swing is complemented with X-axis and between centres the same as K3 but with an additional capacity for between centres of 3168mm.
With machining capacity of this order, stability is critical to achieve high performance.
Combi's engineered concrete fill for the base creates an equilibrium within the structure giving the turning process the basic advantage of consistency even when using higher feed rates and greater depth of cut.
In addition, improved surface finish and consistent tolerance machining from part to part can be readily achieved.
Mounted on the base is a cast iron bed giving a 30 deg slant bed configuration which has been patented by Colchester based on its accessibility for operation.
It also creates a low centre of gravity and new levels of freedom for swarf evacuation from the cutting zone.
The machine saddle and cross-slide assembly uses a triple bearing configuration utilising two linear rails at the front and one at the rear which eliminates any tendency for the saddle to 'crab' and the ballscrew drive is mounted in board of the rails.
This design ensures accuracy and stability are maintained under cut and accommodates the 98 per cent increase in Z-axis thrust available with the new K-Series over the previous machine design.
The guide rail also bridges the bed gap via a further patented design.
The single piece cast headstock fitted with Gamet precision taper roller bearings uses a two-stage ZF clutch/pulley arrangement between the 11kW, 15kW and 22kW GE Fanuc Alpha main spindle motors fitted respectively to the K2, K3 and K4 variants.
The Colchester design of spindle drive gives a 20:1 constant power band ratio for high torque turning at low revolutions.
This is best illustrated with the K4 which can provide a massive 1,900Nm of torque at just 112 revs/min.
In keeping with the target users of Combi, Colchester Lathe has developed the Fanuc 210-TA digital control and Windows 95TM format software around Visual Basic.
The on-screen, icon-driven CAM-based system gives a real time virtual tool display while having full compatibility with other Fanuc G-code based programs.
The open-CNC control software can be programmed by six different methods from a simple digital read-out, through on-screen CAM and electronic handwheel teach and repeat, cut and paste, traditional G-code and by direct numerical control download.
The 960 capacity tool library also utilises icon identification and visual recognition of the tool shape and carries the respective geometric tool data with feed and speed information which can be overridden by the operator.
Rescaling of the tool active zone helps detail viewing of the operation which is a critical function when working on intricate or internal features and a wide selection of macros speed the operator through his setting task.
With new design of slide-aside guarding, access is excellent while large viewing windows coupled with high integrity interlocks and a sliding operator panel means the Colchester Combi introduces new levels of ergonomic operation.
Transmissions supplier installs 21 CNC lathes
First-tier automotive supplier has, since 1998, installed 21 UK-built lathes for hard- and soft-turning of transmission components and a further three machines are ready.
Almost every day there are gloomy reports of a declining manufacturing base in Britain, but there is still some good news, even in large volume production which is supposedly being lost to low-wage countries. For example, first-tier automotive supplier, GKN Driveline, Birmingham, has since 1998 installed 21 UK-built lathes from the MHP division of Geo Kingsbury Machine Tools for hard- and soft-turning of transmission components. A further three machines are ready for pass-off at Geo Kingsbury's Gosport factory.
In addition, a robotically loaded MHP50 CNC lathe is currently in build, due for installation at GKN Driveline in October 2005, for hard turning critical features on the constant velocity joint, or bell, that forms part of front-wheel and four-wheel driveshafts.
There are already five robot-fed MHP machines on the Birmingham site being used for similar work, each teamed with other machinery including hardening, spline rolling, washing plant to form automated manufacturing cells for outer race constant velocity bells.
Production rate is 1,400 components per cell per shift with five operators.
Each automated MHP lathe is fitted with its ABB robot at Geo Kingsbury's Gosport factory and is supplied, after pass-off, to GKN Driveline as a turnkey package, complete with programs.
The other MHP lathes are in manually loaded cells for soft turning operations on bells and tulips, the latter forming part of the plunging joint in a driveshaft nearer to the gearbox.
Mike Poyner, the engineer responsible for project managing the new production cells at the Birmingham factory, said, 'It is our policy to replace as many grinders as possible with hard turning'.
'Each time a lathe is installed it replaces pairs of external, angle-approach grinders'.
'By doing this, there is a six-fold saving in capital investment, amounting to several hundred thousand pounds''.
''Additionally, it takes two hours to change over an external grinder for a new batch compared to 10 minutes for a lathe, so production downtime is less by a factor of 12.' Driving the original change from grinding to hard turning were difficulties with grinding the hub support diameter of the bell and more particularly a shoulder called the back location face, both of which are pre-hardened to 58-62HRC.
The main problem used to be cracking of the location face during grinding, caused by overheating owing to difficulty in projecting sufficient coolant between the grinding wheel and the vertical face.
The earlier grinding operation and the dry hard-turning sequence that has replaced it includes in-cycle machining of a third OD in an unhardened state of 45-48HRC, namely a seating diameter for an ABS pulse ring.
As all turned features need to be concentric with six internal ball tracks, drawing tolerances are tight: +/-0.013mm for the hub support diameter and +/-0.015mm for the ABS diameter, surface finish for both being 1.6 micron.
As regards the back face, 0.15mm of material is machined away to leave a 0.8 micron surface finish.
The Ra figures achieved in practice are significantly lower than these.
Process capability achieved is Cpk 3.66 for the hub support diameter and Cpk 2.65 for the ABS diameter - significantly better than the required Cpk of 1.67 (5 Sigma).
More recently, GKN Driveline has been working in conjunction with Geo Kingsbury to identify inserts for soft turning that would last longer and reduce cycle times.
When machining a bell in its soft state, the incumbent supplier's insert used to result in a 65s turning cycle and it lasted for 70 components.
After research and subsequent trials, a Kennametal insert reduced the cycle to 55s and was found to machine nearly three times as many parts before it needed replacing.
Poyner described the improvement as a 'step change'.
Almost every day there are gloomy reports of a declining manufacturing base in Britain, but there is still some good news, even in large volume production which is supposedly being lost to low-wage countries. For example, first-tier automotive supplier, GKN Driveline, Birmingham, has since 1998 installed 21 UK-built lathes from the MHP division of Geo Kingsbury Machine Tools for hard- and soft-turning of transmission components. A further three machines are ready for pass-off at Geo Kingsbury's Gosport factory.
In addition, a robotically loaded MHP50 CNC lathe is currently in build, due for installation at GKN Driveline in October 2005, for hard turning critical features on the constant velocity joint, or bell, that forms part of front-wheel and four-wheel driveshafts.
There are already five robot-fed MHP machines on the Birmingham site being used for similar work, each teamed with other machinery including hardening, spline rolling, washing plant to form automated manufacturing cells for outer race constant velocity bells.
Production rate is 1,400 components per cell per shift with five operators.
Each automated MHP lathe is fitted with its ABB robot at Geo Kingsbury's Gosport factory and is supplied, after pass-off, to GKN Driveline as a turnkey package, complete with programs.
The other MHP lathes are in manually loaded cells for soft turning operations on bells and tulips, the latter forming part of the plunging joint in a driveshaft nearer to the gearbox.
Mike Poyner, the engineer responsible for project managing the new production cells at the Birmingham factory, said, 'It is our policy to replace as many grinders as possible with hard turning'.
'Each time a lathe is installed it replaces pairs of external, angle-approach grinders'.
'By doing this, there is a six-fold saving in capital investment, amounting to several hundred thousand pounds''.
''Additionally, it takes two hours to change over an external grinder for a new batch compared to 10 minutes for a lathe, so production downtime is less by a factor of 12.' Driving the original change from grinding to hard turning were difficulties with grinding the hub support diameter of the bell and more particularly a shoulder called the back location face, both of which are pre-hardened to 58-62HRC.
The main problem used to be cracking of the location face during grinding, caused by overheating owing to difficulty in projecting sufficient coolant between the grinding wheel and the vertical face.
The earlier grinding operation and the dry hard-turning sequence that has replaced it includes in-cycle machining of a third OD in an unhardened state of 45-48HRC, namely a seating diameter for an ABS pulse ring.
As all turned features need to be concentric with six internal ball tracks, drawing tolerances are tight: +/-0.013mm for the hub support diameter and +/-0.015mm for the ABS diameter, surface finish for both being 1.6 micron.
As regards the back face, 0.15mm of material is machined away to leave a 0.8 micron surface finish.
The Ra figures achieved in practice are significantly lower than these.
Process capability achieved is Cpk 3.66 for the hub support diameter and Cpk 2.65 for the ABS diameter - significantly better than the required Cpk of 1.67 (5 Sigma).
More recently, GKN Driveline has been working in conjunction with Geo Kingsbury to identify inserts for soft turning that would last longer and reduce cycle times.
When machining a bell in its soft state, the incumbent supplier's insert used to result in a 65s turning cycle and it lasted for 70 components.
After research and subsequent trials, a Kennametal insert reduced the cycle to 55s and was found to machine nearly three times as many parts before it needed replacing.
Poyner described the improvement as a 'step change'.
Friday, June 09, 2006
CNC lathes offer stability and power
Price-competitive, two-axis slant bed CNC lathes feature a special one-piece, thermally balanced bed that promotes powerful and stable operation.
The Taiwan Takisawa EX Series of two-axis slant bed CNC lathes now available from Ward CNC of Sheffield, UK, boast a level of high-performance that is unrivalled for machines in this class. Coupled with the use of a special one-piece, thermally balanced bed that promotes powerful and stable operation, the machines' four-track super rigid precision linear guideways and high-speed servo turret all combine with the Fanuc 21iT CNC to provide users with an exceptional 'Japanese quality at Taiwanese prices' package. With swings over the bed of 350mm and 400mm, the EX-106 and EX-108 models have crosslide travels of 280mm and 320mm, respectively, and between centres distances of 455mm and 645mm.
Standard turning diameters are 190mm and 216mm, respectively, and with 152mm and 203mm chucks the machines have respective maximum turning diameters and lengths of 240mm and 320mm, and 350mm and 530mm.
Bar capacities are 43mm for the EX-106 and 52mm for the EX-108, and spindle speeds range from 50-5,000 rev/min (5.5/7.5kW motor) and 60-4,000 rev/min (7.5/11kW) for the two models which both have 12-tool turrets.
Auto tool setting arm, parts catcher, swarf conveyor and programmable quill tailstock are standard; collet chucks and bar feed systems can be provided as options to further widen the machines' cost-effective production capabilities.
The Taiwan Takisawa EX Series of two-axis slant bed CNC lathes now available from Ward CNC of Sheffield, UK, boast a level of high-performance that is unrivalled for machines in this class. Coupled with the use of a special one-piece, thermally balanced bed that promotes powerful and stable operation, the machines' four-track super rigid precision linear guideways and high-speed servo turret all combine with the Fanuc 21iT CNC to provide users with an exceptional 'Japanese quality at Taiwanese prices' package. With swings over the bed of 350mm and 400mm, the EX-106 and EX-108 models have crosslide travels of 280mm and 320mm, respectively, and between centres distances of 455mm and 645mm.
Standard turning diameters are 190mm and 216mm, respectively, and with 152mm and 203mm chucks the machines have respective maximum turning diameters and lengths of 240mm and 320mm, and 350mm and 530mm.
Bar capacities are 43mm for the EX-106 and 52mm for the EX-108, and spindle speeds range from 50-5,000 rev/min (5.5/7.5kW motor) and 60-4,000 rev/min (7.5/11kW) for the two models which both have 12-tool turrets.
Auto tool setting arm, parts catcher, swarf conveyor and programmable quill tailstock are standard; collet chucks and bar feed systems can be provided as options to further widen the machines' cost-effective production capabilities.
Precise CNC lathes intended for 'entry level'
To bring efficient and precise turning to the 'entry-level' user, CNC lathe control system offers visual user-interface and 3D-realtime simulation.
Both the NEF 600 - an EMO 2005 world premiere - and the established NEF 400, make efficient and precise turning possible for the entry-level user, with the highest technology and the latest high-tech components. The user can take advantage of a high level of flexibility, maximum precision and dynamics in the production process. Numerous options allow customised configurations of the machine, to reach maximum productivity in manufacturing.
For decades, the NEF brand has represented lathe-technology at the highest level, ease-of-use and an excellent cost/performance ratio.
With such a successful history, expectations were high when Gildemeister developed the fourth generation of this entry-level machine, which is a high-tech and affordable alternative to low-cost Asian suppliers.
The result is as impressive as it is convincing: both the NEF 400 and the larger NEF 600, which will be presented for the first time at the EMO in Hannover, offer a large number or high-tech components and an overall performance that is unprecedented in the sector of universal turning, making it especially unique.
The impressive innovations of this machine are apparent in the pivoting DMG SlimLinePanel with a stainless steel design, a 15in TFT-screen, high-tech CNCs from Fanuc or Siemens, both with visual user-interface and 3D-realtime simulation, as well as rotational speeds of 4,000 rev/min.
with a drive power of up to 24kW and 720Nm torque.
Another feature unique in this class is the 30 deg slanted bed with four-track design for optimal chip disposal and excellent accessibility.
In addition, the NEF machines feature a large work area combined with a traversable steady-rest and a fast 8x-turret, for high productivity and flexibility.
Chuck workpieces with diameters up to 350mm.
(NEF 400) or 600mm.
(NEF 600), and shaft workpieces with lengths up to 650 or 1200mm can be machined in the shortest possible time.
All this is achieved with the highest level of precision and with excellent surface quality, ensured by digital drive technology for the main spindle and sturdy linear guide-ways.
Additional features of this pioneering machine series are the tailstock with hydraulic quill, low space requirements of the fully enclosed machine in Space Green design (Metallic optional), advanced state-of-the-art central lubrication and integrated safety technology (Safety Integrated/Dual Check Safety).
Innovations - NEF 400 and NEF 600: * Pivoting DMG SlimLinePanel with 15in TFT-screen and state-of-the-art 3D software.
* Excellent shaft machining capabilities due to 4-track bed and traversable steady rest.
* 8x disk turret.
* Traversable tailstock with hydraulic quill.
* Dynamic linear guide-ways.
* Improved ergonomics and chip disposal through 30 deg slanted bed.
* Digital drive on the main spindle for best surface qualities and highest precision, plus high rotational speeds up to 4,000 rev/min as well as drive performance up to 15/24kW and 400/720Nm torque.
* Large work area for chuck workpieces up to 350/600mm and shaft workpieces up to 650/1200mm length.
Both the NEF 600 - an EMO 2005 world premiere - and the established NEF 400, make efficient and precise turning possible for the entry-level user, with the highest technology and the latest high-tech components. The user can take advantage of a high level of flexibility, maximum precision and dynamics in the production process. Numerous options allow customised configurations of the machine, to reach maximum productivity in manufacturing.
For decades, the NEF brand has represented lathe-technology at the highest level, ease-of-use and an excellent cost/performance ratio.
With such a successful history, expectations were high when Gildemeister developed the fourth generation of this entry-level machine, which is a high-tech and affordable alternative to low-cost Asian suppliers.
The result is as impressive as it is convincing: both the NEF 400 and the larger NEF 600, which will be presented for the first time at the EMO in Hannover, offer a large number or high-tech components and an overall performance that is unprecedented in the sector of universal turning, making it especially unique.
The impressive innovations of this machine are apparent in the pivoting DMG SlimLinePanel with a stainless steel design, a 15in TFT-screen, high-tech CNCs from Fanuc or Siemens, both with visual user-interface and 3D-realtime simulation, as well as rotational speeds of 4,000 rev/min.
with a drive power of up to 24kW and 720Nm torque.
Another feature unique in this class is the 30 deg slanted bed with four-track design for optimal chip disposal and excellent accessibility.
In addition, the NEF machines feature a large work area combined with a traversable steady-rest and a fast 8x-turret, for high productivity and flexibility.
Chuck workpieces with diameters up to 350mm.
(NEF 400) or 600mm.
(NEF 600), and shaft workpieces with lengths up to 650 or 1200mm can be machined in the shortest possible time.
All this is achieved with the highest level of precision and with excellent surface quality, ensured by digital drive technology for the main spindle and sturdy linear guide-ways.
Additional features of this pioneering machine series are the tailstock with hydraulic quill, low space requirements of the fully enclosed machine in Space Green design (Metallic optional), advanced state-of-the-art central lubrication and integrated safety technology (Safety Integrated/Dual Check Safety).
Innovations - NEF 400 and NEF 600: * Pivoting DMG SlimLinePanel with 15in TFT-screen and state-of-the-art 3D software.
* Excellent shaft machining capabilities due to 4-track bed and traversable steady rest.
* 8x disk turret.
* Traversable tailstock with hydraulic quill.
* Dynamic linear guide-ways.
* Improved ergonomics and chip disposal through 30 deg slanted bed.
* Digital drive on the main spindle for best surface qualities and highest precision, plus high rotational speeds up to 4,000 rev/min as well as drive performance up to 15/24kW and 400/720Nm torque.
* Large work area for chuck workpieces up to 350/600mm and shaft workpieces up to 650/1200mm length.
Saturday, June 03, 2006
CNC lathe designed for high metal removal
A massive high grade SG iron casting and optimal chip clearance provides the basis for high level of swarf removal on the latest CNC lathe with a cutting diameter of 450mm.
A massive high grade SG iron casting creating a 5.2 tonne, 45 deg slant bed with optimal chip clearance provides the basis for high level of swarf removal on the latest Dugard Eagle 300 CNC lathe. As part of the specification the machine can be customised to carry the most appropriate spindle and drive system package to suit the intended production use. Available from C Dugard of Hove, Sussex, UK, this competitively priced machine, with swing over the bed of 600mm and a maximum cutting diameter of 450mm by 700mm cutting length, provides the choice of three drives.
These provide the option of 35 to 3,500 rev/min from a 20kW AC motor, 2,500 rev/min through a 18.5kW motor and high torque two-speed gearbox, or 25 to 3,500 rev/min from a 22kW drive.
The hydraulic 10 station turret with 0.3s index time is mounted on linear guideways to enable rapid traverse rates of 20m/min in X and 24m/min in Y to be achieved.
Positioning accuracy is two microns and repeatability +0.0013mm in X and four microns for positioning and +0.0025mm repeatability in Z.
A hydraulic tailstock with 85mm quill diameter and 120mm programmable quill travel is standard with programmable auto-positioning an option.
Barfeed is optional for stock size up to 77mm diameter with parts-catcher and choice of manual or automatic tool setting probes.
As a further option, a 315mm power chuck with eight station turret can be specified in preference to the standard 252mm hydraulic chuck with through bore.
There are further options of CNC control systems through C.
Dugard from both Siemens and Fanuc.
A massive high grade SG iron casting creating a 5.2 tonne, 45 deg slant bed with optimal chip clearance provides the basis for high level of swarf removal on the latest Dugard Eagle 300 CNC lathe. As part of the specification the machine can be customised to carry the most appropriate spindle and drive system package to suit the intended production use. Available from C Dugard of Hove, Sussex, UK, this competitively priced machine, with swing over the bed of 600mm and a maximum cutting diameter of 450mm by 700mm cutting length, provides the choice of three drives.
These provide the option of 35 to 3,500 rev/min from a 20kW AC motor, 2,500 rev/min through a 18.5kW motor and high torque two-speed gearbox, or 25 to 3,500 rev/min from a 22kW drive.
The hydraulic 10 station turret with 0.3s index time is mounted on linear guideways to enable rapid traverse rates of 20m/min in X and 24m/min in Y to be achieved.
Positioning accuracy is two microns and repeatability +0.0013mm in X and four microns for positioning and +0.0025mm repeatability in Z.
A hydraulic tailstock with 85mm quill diameter and 120mm programmable quill travel is standard with programmable auto-positioning an option.
Barfeed is optional for stock size up to 77mm diameter with parts-catcher and choice of manual or automatic tool setting probes.
As a further option, a 315mm power chuck with eight station turret can be specified in preference to the standard 252mm hydraulic chuck with through bore.
There are further options of CNC control systems through C.
Dugard from both Siemens and Fanuc.
Toolroom CNC mill/turn lathes unveiled
Full production models of the Harrison Alpha X Series, which includes the all-new 3-axis Alpha 1550XM model - with full C-axis and milling capability - were unveiled in the UK in 2005.
Harrison Lathes' eye-catching new Alpha X Series, which attracted worldwide interest from the media, industry analysts and global customers alike at EMO 2005 in September, has now had its official launch in the domestic market. Full production models of the Alpha X Series, which includes the all-new 3-axis Alpha 1550XM model - the first Alpha lathe ever produced with full C-axis and milling capability - were unveiled in the Midlands courtesy of Harrison principal distributor, Datamach of Coventry. The late 2005 event attracted unprecedented interest in the new lathes from many of the distributor's large existing customer-base, and potential customers, who started arriving early in the day to view the new Alpha line-up and other advanced-technology Harrison lathes.
These included independent engineering companies, representatives from the manufacturing sector and other engineering specialists.
Datamach's sales director, Lorraine Lloyd, said: 'It was easily our best-ever customer event.
We had representatives from approximately 30 companies throughout the central region, including Lincoln, Oxford, Northampton also the Birmingham and Leicester areas.
There is huge interest in the new machines and customers we had invited were arriving from 8.30am until after 8pm.' She said that a string of important orders had been placed for Harrison Alpha machines at the Datamach launch event, including a V390 centre lathe, an Alpha 1550XS and an Alpha 1800S (3m 120mm spindle bore lathe); the latter being from Summit Precision Engineering , of Solihull, West Midlands.
The company had earlier in the month become the first in the UK to take delivery of a massive 4m Alpha 1800S (170mm spindle bore) lathe, following a major contract win for Scottish offshore oil industry equipment.
Dr Stephen Le Beau, Product Strategy and Marketing director said: 'The introduction of the new Alpha X Series is already making a big impact on the international lathes market, with orders being received from across the globe, most notably in Europe, the USA and Australia.
The launch and availability of the Alpha X range in the UK represents another major step forward for Harrison and the undoubted success of Datamach's launch day, with so many customers coming to see the machines for themselves, clearly demonstrates their enthusiasm for Harrison's lathe technology and quality manufacturing.
It also reflects the importance of the trust and confidence which customers have in Datamach , not only to supply market-leading lathes which deliver maximum engineering performance with lower component production costs, but also to provide a complete programme of after-sales support for total peace of mind following the initial investment.' * About Harrison - Harrison - a member of 600 Group, the UK's largest machine tool company - has successfully combined new, market-leading touchscreen technologies and designs with traditional manufacturing quality in the Alpha X Series.
Harrison design engineers have incorporated no fewer than 85 individual technical enhancements with the result that the new range provides even faster turning speeds and more power plus the very latest G E Fanuc-based control system available.
This highly advanced new 'total system solution' has been specially developed by Harrison and Fanuc for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.
The full Harrison Alpha X Series, officially launched at EMO 2005, comprises the following lathes: ALPHA XT - Alpha 1350XT, Alpha 1400XT, Alpha 1460XT, Alpha 1550XT, Alpha 1800XT; ALPHA XS - Alpha 1350XS, Alpha 1400XS, Alpha 1460XS, Alpha 1550XS, Alpha 1800XS; ALPHA XM - Alpha 1550XM.
The ideal choice for all sub- contractors, toolrooms, Research and Development facilities and all education and training applications, every Alpha X Series lathe is manufactured to toolroom standards (DIN 8605) at one of Europe's largest lathe manufacturing plants in Yorkshire, England.
Harrison Lathes' eye-catching new Alpha X Series, which attracted worldwide interest from the media, industry analysts and global customers alike at EMO 2005 in September, has now had its official launch in the domestic market. Full production models of the Alpha X Series, which includes the all-new 3-axis Alpha 1550XM model - the first Alpha lathe ever produced with full C-axis and milling capability - were unveiled in the Midlands courtesy of Harrison principal distributor, Datamach of Coventry. The late 2005 event attracted unprecedented interest in the new lathes from many of the distributor's large existing customer-base, and potential customers, who started arriving early in the day to view the new Alpha line-up and other advanced-technology Harrison lathes.
These included independent engineering companies, representatives from the manufacturing sector and other engineering specialists.
Datamach's sales director, Lorraine Lloyd, said: 'It was easily our best-ever customer event.
We had representatives from approximately 30 companies throughout the central region, including Lincoln, Oxford, Northampton also the Birmingham and Leicester areas.
There is huge interest in the new machines and customers we had invited were arriving from 8.30am until after 8pm.' She said that a string of important orders had been placed for Harrison Alpha machines at the Datamach launch event, including a V390 centre lathe, an Alpha 1550XS and an Alpha 1800S (3m 120mm spindle bore lathe); the latter being from Summit Precision Engineering , of Solihull, West Midlands.
The company had earlier in the month become the first in the UK to take delivery of a massive 4m Alpha 1800S (170mm spindle bore) lathe, following a major contract win for Scottish offshore oil industry equipment.
Dr Stephen Le Beau, Product Strategy and Marketing director said: 'The introduction of the new Alpha X Series is already making a big impact on the international lathes market, with orders being received from across the globe, most notably in Europe, the USA and Australia.
The launch and availability of the Alpha X range in the UK represents another major step forward for Harrison and the undoubted success of Datamach's launch day, with so many customers coming to see the machines for themselves, clearly demonstrates their enthusiasm for Harrison's lathe technology and quality manufacturing.
It also reflects the importance of the trust and confidence which customers have in Datamach , not only to supply market-leading lathes which deliver maximum engineering performance with lower component production costs, but also to provide a complete programme of after-sales support for total peace of mind following the initial investment.' * About Harrison - Harrison - a member of 600 Group, the UK's largest machine tool company - has successfully combined new, market-leading touchscreen technologies and designs with traditional manufacturing quality in the Alpha X Series.
Harrison design engineers have incorporated no fewer than 85 individual technical enhancements with the result that the new range provides even faster turning speeds and more power plus the very latest G E Fanuc-based control system available.
This highly advanced new 'total system solution' has been specially developed by Harrison and Fanuc for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.
The full Harrison Alpha X Series, officially launched at EMO 2005, comprises the following lathes: ALPHA XT - Alpha 1350XT, Alpha 1400XT, Alpha 1460XT, Alpha 1550XT, Alpha 1800XT; ALPHA XS - Alpha 1350XS, Alpha 1400XS, Alpha 1460XS, Alpha 1550XS, Alpha 1800XS; ALPHA XM - Alpha 1550XM.
The ideal choice for all sub- contractors, toolrooms, Research and Development facilities and all education and training applications, every Alpha X Series lathe is manufactured to toolroom standards (DIN 8605) at one of Europe's largest lathe manufacturing plants in Yorkshire, England.
Tuesday, May 30, 2006
Contractor turns to CNC for turning 'one-offs'
A recent convert to CNC machining with the installation of a XYZ ProTURN VL 355 lathe, Hydrojet Precision Engineering specialises in the manufacture from high-grade stainless steels of bespoke parts such as nozzles, nozzle holders, fittings and lances for waterjetting applications. The many and varied uses of high-pressure waterjetting demand a multitude of specialist delivery systems, and that is where Hydrojet comes into the picture. Formed in 1996 by brothers Michael and Graham Wilkes, this Bromsgrove, Worcestershire company is a leading manufacturer and supplier of high and ultra-high pressure (up to 36,000 lb/in2) waterjetting accessories and consumables.
But why opt for a CNC machine tool when manual machining of one-offs and small batches, often dispatched on the day of order, has been sufficient to establish an industry-wide reputation for quality, reliability and speed of response?
'Buying the ProTURN has undoubtedly made life easier for us,' says Graham Wilkes.
'We were working on an extremely awkward job, knowing that one mistake could scrap the component, when we had a visit from XYZ.
It was pointed out to us that this particular job could be programmed quickly and easily on a manual/CNC lathe and the program checked before machining began, thereby avoiding a costly mistake with a one-off and providing a program that could be retrieved at any time for a repeat order.
We have actually had that same job since installing the new lathe,' adds Michael Wilkes, 'And it was perfect.
Initially we were apprehensive about moving to CNC but with a day's training it proved to be totally painless.
The manual/CNC option is great, as we can, for instance, intervene to change the feedrate while the program is actually running.
This ensures we achieve the optimum chip breaking conditions when machining difficult materials.' The 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 provides Hydrojet with a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC.
This degree of flexibility is ideal for a business that has made its name with the speedy production of one-offs and small batches, and it is the 'traking' feature of the ProtoTRAK VL control that makes it possible.
In CNC mode the electronic handwheels on the machine allow the operator to 'trak' through a program while controlling the speed at which the machine moves.
Slow or stop winding the handles and the machine also slows or stops, a unique feature that eliminates any possibility of collision.
'Our business has grown mainly as a result of word of mouth recommendations,' says Michael Wilkes, 'Although we still regard ourselves as skilled machinists rather than businessmen.
We concentrate our resources mainly on turning and to a lesser extent milling, but the demand for our products is such that we needed to find ways to meet that demand without taking on people, moving to larger premises or working longer hours.
But why opt for a CNC machine tool when manual machining of one-offs and small batches, often dispatched on the day of order, has been sufficient to establish an industry-wide reputation for quality, reliability and speed of response?
'Buying the ProTURN has undoubtedly made life easier for us,' says Graham Wilkes.
'We were working on an extremely awkward job, knowing that one mistake could scrap the component, when we had a visit from XYZ.
It was pointed out to us that this particular job could be programmed quickly and easily on a manual/CNC lathe and the program checked before machining began, thereby avoiding a costly mistake with a one-off and providing a program that could be retrieved at any time for a repeat order.
We have actually had that same job since installing the new lathe,' adds Michael Wilkes, 'And it was perfect.
Initially we were apprehensive about moving to CNC but with a day's training it proved to be totally painless.
The manual/CNC option is great, as we can, for instance, intervene to change the feedrate while the program is actually running.
This ensures we achieve the optimum chip breaking conditions when machining difficult materials.' The 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 provides Hydrojet with a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC.
This degree of flexibility is ideal for a business that has made its name with the speedy production of one-offs and small batches, and it is the 'traking' feature of the ProtoTRAK VL control that makes it possible.
In CNC mode the electronic handwheels on the machine allow the operator to 'trak' through a program while controlling the speed at which the machine moves.
Slow or stop winding the handles and the machine also slows or stops, a unique feature that eliminates any possibility of collision.
'Our business has grown mainly as a result of word of mouth recommendations,' says Michael Wilkes, 'Although we still regard ourselves as skilled machinists rather than businessmen.
We concentrate our resources mainly on turning and to a lesser extent milling, but the demand for our products is such that we needed to find ways to meet that demand without taking on people, moving to larger premises or working longer hours.
Competition with machine tools and skills
Great Britain can compete successfully on the world stage, according to Phil Round, chief executive of the Herefordshire and Worcestershire Group Training Associations (GTAs). 'I'm convinced that motivated workforces using the appropriate production equipment and armed with first-class skills can enable UK companies to be global competitors,' he exclaims. With an obvious bias, Phil Round enthusiastically promotes the benefits of continual skills development - in terms of companies' profit margins as well as increased rewards and job satisfaction for their employees - and, unsurprisingly, he vigorously promotes the various training courses available via his organisation, which is a Learning and Skills Council-accredited Centre of Vocational Excellence.
Proudly, he states that the GTA is the largest college provider of apprenticeships in the area.
'The most important thing to remember about us is the fact that we are financed and controlled by local companies - firms of all sizes across various industry and business sectors - and we therefore work in partnership with these companies to develop training courses that are designed to produce maximum benefit for the companies, their employees [the trainees] and the local communities.
'I have no doubt that UK companies, if armed with the correct skills and equipment, can retain their world status - and GTA members like Special Metals Wiggin, Bulmers and Sun Valley Foods consistently prove that!' Much of Phil Round's talk of creating 'world class' employees is based around the provision of an extensive number of courses that are tailor-made to the trainee/partner company, and they include the delivery of NVQ qualifications in engineering manufacture, design, engineering maintenance and engineering production.
In addition to focused courses that cover fluid power (pneumatics and hydraulics) draughting, computer-aided design, welding and fabrication (MIG and TIG welding, plasma cutting) and industrial electrical courses (motor power control and diagnostics, for example), the engineering training centres at both Hereford and Worcester are characterised by impressive 'shopfloors'.
These serve as home to the 200 or so apprentices that all undertake substantial periods of training on turning, milling and CNC machining courses.
The key to success, he continues, is not only dependent on bright and enthusiastic trainees, but it also relies on the use of the correct calibre of equipment.
'And in the case of machine tools, this means utilising machines that are industry-standard and fit for purpose.
'We haveve invested approximately GBP 1 million during the past three years on re-equipping our Hereford and Worcester centres to make them among the best such facilities in the country, and we certainly wouldn't have spent such a sum if we thought that Great Britain was in terminal decline.' Much of that capital expenditure has been invested in machines supplied by Gate Machinery International, the Watford-based specialist supplier that, says Phil Round, 'has played a key role in upgrading our facilities with a superb portfolio of predominantly two- and three-axis turning and milling machines'.
All the machines are of quality build and have high-class specifications, and they include the user-friendly functionality of Anilam DRO/CNC systems - multi-axis control technology that suits all possible skill levels and needs.
'Around 75% of the investment has been made at the Worcester Training Centre, where in the 10,000ft2 of refurbished training workshops and lecture rooms we've replicated our successful Hereford training area,' says Phil Round.
'The new Worcester centre, operated in partnership with Worcester College of Technology, commenced training in March 2005, and could not have come at a better time, since a recent Strategic Area Review confirms manufacturing and engineering as a priority for Herefordshire and Worcestershire, and forecasts that nearly 11,000 new employees will be required locally in suitable disciplines by the year 2012.' With a pot of money and an extensive shopping list, it was vital that Phil Round and his team spent every penny in the most effective way.
'It soon became clear that our budget would go furthest and provide all the machines we required - with no detriment to machine specification and quality - with Gate Machinery International,' he confirms.
'In addition, based on the highly professional way in which the Gate team fulfilled their obligations when we re-equipped the Hereford centre - the machine installation programme was carried out with military precision - coupled with such a high level of back-up and after-sales service, it really wasn't a difficult decision to choose Gate again.' Of highly rigid construction, the Gate Eclipse ECM-1 CNC turret mill exemplifies what Phil Round describes as 'affordable quality' with a high-class specification.
The machine's Anilam 5300 CNC allows both conversational and G-code programming which enables the instructors to fully follow the CNC curriculum.
With a table of 1,067 mm by 230 mm, the machine can accommodate loads of 125 kgs, which is more than adequate for the workpieces processed - predominantly one-offs for the toolmaking and maintenance machinist environments, though batchwork is also progressed.
The machine has X, Y and Z (quill) axes travels of 660mm by 305mm by 100mm complemented by a powered knee travel in Z of 406mm (optional).
Variable spindle speeds as standard are from 60 to 4,200 revs/min and rigid tapping is optional.
Anilam off-line programming software enables the control to be replicated in a classroom environment, allowing programs to be created off-line and sent to the machine via DNC link or floppy drive.
In the event, Gate Machinery International has supplied a total of 31 machines to the Hereford and Worcester centres, including turret and CNC milling, heavy duty and centre lathe capacity, and variable speed and CNC turning machines.
With this armoury of production equipment complementing such a comprehensive training syllabus, Phil Round is justifiably proud of what is being achieved in Hereford and Worcester.
'The area may be regarded by some as a rural backwater,' he concludes.
'But we are leading the way when it comes to utilising world-class equipment and training courses that produce world-class engineers.'
Proudly, he states that the GTA is the largest college provider of apprenticeships in the area.
'The most important thing to remember about us is the fact that we are financed and controlled by local companies - firms of all sizes across various industry and business sectors - and we therefore work in partnership with these companies to develop training courses that are designed to produce maximum benefit for the companies, their employees [the trainees] and the local communities.
'I have no doubt that UK companies, if armed with the correct skills and equipment, can retain their world status - and GTA members like Special Metals Wiggin, Bulmers and Sun Valley Foods consistently prove that!' Much of Phil Round's talk of creating 'world class' employees is based around the provision of an extensive number of courses that are tailor-made to the trainee/partner company, and they include the delivery of NVQ qualifications in engineering manufacture, design, engineering maintenance and engineering production.
In addition to focused courses that cover fluid power (pneumatics and hydraulics) draughting, computer-aided design, welding and fabrication (MIG and TIG welding, plasma cutting) and industrial electrical courses (motor power control and diagnostics, for example), the engineering training centres at both Hereford and Worcester are characterised by impressive 'shopfloors'.
These serve as home to the 200 or so apprentices that all undertake substantial periods of training on turning, milling and CNC machining courses.
The key to success, he continues, is not only dependent on bright and enthusiastic trainees, but it also relies on the use of the correct calibre of equipment.
'And in the case of machine tools, this means utilising machines that are industry-standard and fit for purpose.
'We haveve invested approximately GBP 1 million during the past three years on re-equipping our Hereford and Worcester centres to make them among the best such facilities in the country, and we certainly wouldn't have spent such a sum if we thought that Great Britain was in terminal decline.' Much of that capital expenditure has been invested in machines supplied by Gate Machinery International, the Watford-based specialist supplier that, says Phil Round, 'has played a key role in upgrading our facilities with a superb portfolio of predominantly two- and three-axis turning and milling machines'.
All the machines are of quality build and have high-class specifications, and they include the user-friendly functionality of Anilam DRO/CNC systems - multi-axis control technology that suits all possible skill levels and needs.
'Around 75% of the investment has been made at the Worcester Training Centre, where in the 10,000ft2 of refurbished training workshops and lecture rooms we've replicated our successful Hereford training area,' says Phil Round.
'The new Worcester centre, operated in partnership with Worcester College of Technology, commenced training in March 2005, and could not have come at a better time, since a recent Strategic Area Review confirms manufacturing and engineering as a priority for Herefordshire and Worcestershire, and forecasts that nearly 11,000 new employees will be required locally in suitable disciplines by the year 2012.' With a pot of money and an extensive shopping list, it was vital that Phil Round and his team spent every penny in the most effective way.
'It soon became clear that our budget would go furthest and provide all the machines we required - with no detriment to machine specification and quality - with Gate Machinery International,' he confirms.
'In addition, based on the highly professional way in which the Gate team fulfilled their obligations when we re-equipped the Hereford centre - the machine installation programme was carried out with military precision - coupled with such a high level of back-up and after-sales service, it really wasn't a difficult decision to choose Gate again.' Of highly rigid construction, the Gate Eclipse ECM-1 CNC turret mill exemplifies what Phil Round describes as 'affordable quality' with a high-class specification.
The machine's Anilam 5300 CNC allows both conversational and G-code programming which enables the instructors to fully follow the CNC curriculum.
With a table of 1,067 mm by 230 mm, the machine can accommodate loads of 125 kgs, which is more than adequate for the workpieces processed - predominantly one-offs for the toolmaking and maintenance machinist environments, though batchwork is also progressed.
The machine has X, Y and Z (quill) axes travels of 660mm by 305mm by 100mm complemented by a powered knee travel in Z of 406mm (optional).
Variable spindle speeds as standard are from 60 to 4,200 revs/min and rigid tapping is optional.
Anilam off-line programming software enables the control to be replicated in a classroom environment, allowing programs to be created off-line and sent to the machine via DNC link or floppy drive.
In the event, Gate Machinery International has supplied a total of 31 machines to the Hereford and Worcester centres, including turret and CNC milling, heavy duty and centre lathe capacity, and variable speed and CNC turning machines.
With this armoury of production equipment complementing such a comprehensive training syllabus, Phil Round is justifiably proud of what is being achieved in Hereford and Worcester.
'The area may be regarded by some as a rural backwater,' he concludes.
'But we are leading the way when it comes to utilising world-class equipment and training courses that produce world-class engineers.'
Saturday, May 27, 2006
7-axis turning cell with automatic loading system
New from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system.
Extending its highly competitive and cost-effective 'Lights-out' machine package strategy for the top-selling Tornado range of CNC turning centres, new from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system. Available from Colchestersales of Heckmondwike, the Tornado T6MS is a true integrated mill/turning cell devised for maximum utilisation involving unmanned operation. Now with loading and unloading of components performed by purpose developed automation, that operates within the confines of the machine without additional guarding or fencing, it sets a new standard for economic production at, in true Colchester Lathe tradition, an affordable price.
The automation is fully programmable via teach pendant and operates through the Fanuc 18i-TB control with Manual Guide i software on the machine as standard while being integrated with Colchester Lathe developed automation programs.
As a result, loading sequences are combined with first and second chucking operations with automatic part transfer between main and subspindle for parts up to 80 mm diameter by 100 mm long and weighing up to 5 kg.
The machine concept involves a loading beam mounted above and onto the headstock and running parallel to the centre line or Z-axis to link component storage at the headstock side of the machine to the cutting zone.
Powered via ballscrew and servo drives a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems of either part stockers, carousel, palletising or conveyor systems.
The different types of material and work handling systems are able to manipulate raw material supply to the main spindle and accept the off-load of completed parts from the main or subspindle enabling the production cycle to continue independent of the loading system.
The loading system therefore is able to carry on to complete the handling sequence with the part storage elements and is able to be parked clear of the machine working area to enable normal machine operation.
The Tornado T6MS has a 440 m swing over bed and 220 mm maximum turned diameter by 450 mm long with a 54 mm bar capacity and 130 mm chuck size.
The 15 kW, 6,000 revs/min main and 5.5 kW, 6,000 revs/min subspindle are serviced by a 12 station all-driven tool turret with 3.7 kW, 5,000 revs/min drive.
Rapid traverse rates are 30 m/min in Z and 25 m/min in X.
Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that uses an encapsulated polymer concrete base fill with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.
Extending its highly competitive and cost-effective 'Lights-out' machine package strategy for the top-selling Tornado range of CNC turning centres, new from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system. Available from Colchestersales of Heckmondwike, the Tornado T6MS is a true integrated mill/turning cell devised for maximum utilisation involving unmanned operation. Now with loading and unloading of components performed by purpose developed automation, that operates within the confines of the machine without additional guarding or fencing, it sets a new standard for economic production at, in true Colchester Lathe tradition, an affordable price.
The automation is fully programmable via teach pendant and operates through the Fanuc 18i-TB control with Manual Guide i software on the machine as standard while being integrated with Colchester Lathe developed automation programs.
As a result, loading sequences are combined with first and second chucking operations with automatic part transfer between main and subspindle for parts up to 80 mm diameter by 100 mm long and weighing up to 5 kg.
The machine concept involves a loading beam mounted above and onto the headstock and running parallel to the centre line or Z-axis to link component storage at the headstock side of the machine to the cutting zone.
Powered via ballscrew and servo drives a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems of either part stockers, carousel, palletising or conveyor systems.
The different types of material and work handling systems are able to manipulate raw material supply to the main spindle and accept the off-load of completed parts from the main or subspindle enabling the production cycle to continue independent of the loading system.
The loading system therefore is able to carry on to complete the handling sequence with the part storage elements and is able to be parked clear of the machine working area to enable normal machine operation.
The Tornado T6MS has a 440 m swing over bed and 220 mm maximum turned diameter by 450 mm long with a 54 mm bar capacity and 130 mm chuck size.
The 15 kW, 6,000 revs/min main and 5.5 kW, 6,000 revs/min subspindle are serviced by a 12 station all-driven tool turret with 3.7 kW, 5,000 revs/min drive.
Rapid traverse rates are 30 m/min in Z and 25 m/min in X.
Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that uses an encapsulated polymer concrete base fill with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.
CNC lathes chosen for college facility
Some GBP 3 million has already been allocated to a College's Technology Suite, for which the CNC lathe installations have been a focal point of a GBP 700,000 investment in new equipment.
The reason East Tyrone College of Further and Higher Education elected to spend GBP 140,000 with Ireland's Colchester Lathe sole dealership, Gillen Machine Tools, was it needed machines installed that would be recognised and accepted by local industry as being the standard of equipment that would provide trainees and engineering students with the experience and knowledge that would be useful in their future careers. As Alastair Booth, lecturer in engineering pointed out: 'With the equipment we have credibility as a top training establishment and are able to perform a positive service to industry in the area and also increase our revenue generation.' East Tyrone College of Further and High Education is based in Dungannon to service Northern Ireland and the border area and has been funded to the tune of almost GBP 20 million for new buildings and facilities. Some GBP 3 million has already been allocated to the Technology Suite for which the Colchester Lathe installations have been a focal point of the GBP 700,000 investment in new equipment.
As a result of 10 years in concept, six years planning and the last three years spent on detail, the Technology Suite will encompass a very modern machine shop, welding and fabrication facility, rapid prototyping, advanced CADCAM and a structural testing and diagnostics suite.
There are also courses available on subject areas such as programmable logic control, customised for local industry and during 2006, a new home automation course is being planned.
The college is the first centre in Ireland to gain certification as an EIB/KNX centre for advanced training in the configuration of bus devices in lighting, blinds control, safety and security and energy cost reduction, The first course is scheduled for February in a new course delivery suite.
Enrolling almost 15,000 students a year, it employs 75 full-time staff and 100 part-time people.
There are also 25 'out centres' and mobile IT vehicles kitted out with 16 laptops that provide Information Technology classes in the community.
The Colchester Lathe contract was clinched following a visit to an Open House set up by Gillen Machine Tools in its showroom at Ballymena when Alastair Booth and his team took the opportunity to see the Colchester machines in action.
In particular they wanted to bridge the manual to CNC technology gap and while they decided that five Colchester Student 2500 conventional lathes fitted with Heidenhain digital readouts gave the perfect training platform/machine combination, providing 'real' turning experience at a very competitive price, it was the Colchester Combi K2 lathe that came across as the ideal solution for what they were seeking in higher technology machining.
Says Alastair Booth: 'It is the versatility of the machine and the Fanuc 21 Oi TA multi-functional control with the user friendliness of Microsoft Windows that provides the ideal bridge we were seeking.
The machine has six ways in which you can input instructions which covers a wide range of programming avenues.' With the Combi, the operator can manually turn a part using the electronic handwheels, and use the control simply as a digital readout for positioning.
He also has the facility to create his own canned cycles as well as using the Colchester developed cycles in the memory or cut and paste to make up toolpaths.
Setting is helped by access to the extensive tool library which can hold up to 960 tools.
There is also the simple teach/repeat memory and on-screen CADCAM, with icon-based commands and, for the more advanced user, conventional CNC programming can be performed using G-Codes.
Programs can also be downloaded by DNC or input from a 'flash card' taken from a PC.
To which Booth adds: 'We also have a full CNC machine in the Combi K2 for repeat cycles that will have the respect of any engineering manager for the way it will perform in production.' Indeed, the College already has the support of 10 local companies taking up a 10 week introductory course to provide a sound understanding of CNC machining techniques and a course for manual machinists to upgrade to CNC.
According to Maria Hackett, head of school and job skills co-ordinator: 'The Dungannon area is the most active in Northern Ireland for engineering and in particular fabrication.
However, there is an increasing number of businesses that want to break into, or upgrade from manual to CNC machining and that is a prime area for us to satisfy with the new equipment.
With the addition of part time staff we will then introduce customised courses for local industry.' Modern apprenticeship courses are also being run on a day-release basis as well as full time BTEC National Diploma in Engineering.
And indeed, keen to catch the prospective student and with a view to nurturing an interest in engineering, the College has structured a series of two-day courses for local school children in conjunction with local businesses to give them an introduction to what engineering is all about.
As part of the two-day course, the children will be involved in projects such as making a CD holder and even be taken to a local engineering company to see real 'live' manufacturing.
Meanwhile, through the Women in Engineering WISE programme, European funding was gained by the College to train 20 women to NVQ Level 2 followed by placement with local employers.
With fresh ideas and schemes like these, Booth is adamant that selecting the right equipment was so crucial.
But as he maintains: 'We will need help with training and retraining as well as technical assistance, and part of our decision to buy the Colchester machines from Gillen Machine Tools is that we will be able to draw heavily on support in times of need.'
The reason East Tyrone College of Further and Higher Education elected to spend GBP 140,000 with Ireland's Colchester Lathe sole dealership, Gillen Machine Tools, was it needed machines installed that would be recognised and accepted by local industry as being the standard of equipment that would provide trainees and engineering students with the experience and knowledge that would be useful in their future careers. As Alastair Booth, lecturer in engineering pointed out: 'With the equipment we have credibility as a top training establishment and are able to perform a positive service to industry in the area and also increase our revenue generation.' East Tyrone College of Further and High Education is based in Dungannon to service Northern Ireland and the border area and has been funded to the tune of almost GBP 20 million for new buildings and facilities. Some GBP 3 million has already been allocated to the Technology Suite for which the Colchester Lathe installations have been a focal point of the GBP 700,000 investment in new equipment.
As a result of 10 years in concept, six years planning and the last three years spent on detail, the Technology Suite will encompass a very modern machine shop, welding and fabrication facility, rapid prototyping, advanced CADCAM and a structural testing and diagnostics suite.
There are also courses available on subject areas such as programmable logic control, customised for local industry and during 2006, a new home automation course is being planned.
The college is the first centre in Ireland to gain certification as an EIB/KNX centre for advanced training in the configuration of bus devices in lighting, blinds control, safety and security and energy cost reduction, The first course is scheduled for February in a new course delivery suite.
Enrolling almost 15,000 students a year, it employs 75 full-time staff and 100 part-time people.
There are also 25 'out centres' and mobile IT vehicles kitted out with 16 laptops that provide Information Technology classes in the community.
The Colchester Lathe contract was clinched following a visit to an Open House set up by Gillen Machine Tools in its showroom at Ballymena when Alastair Booth and his team took the opportunity to see the Colchester machines in action.
In particular they wanted to bridge the manual to CNC technology gap and while they decided that five Colchester Student 2500 conventional lathes fitted with Heidenhain digital readouts gave the perfect training platform/machine combination, providing 'real' turning experience at a very competitive price, it was the Colchester Combi K2 lathe that came across as the ideal solution for what they were seeking in higher technology machining.
Says Alastair Booth: 'It is the versatility of the machine and the Fanuc 21 Oi TA multi-functional control with the user friendliness of Microsoft Windows that provides the ideal bridge we were seeking.
The machine has six ways in which you can input instructions which covers a wide range of programming avenues.' With the Combi, the operator can manually turn a part using the electronic handwheels, and use the control simply as a digital readout for positioning.
He also has the facility to create his own canned cycles as well as using the Colchester developed cycles in the memory or cut and paste to make up toolpaths.
Setting is helped by access to the extensive tool library which can hold up to 960 tools.
There is also the simple teach/repeat memory and on-screen CADCAM, with icon-based commands and, for the more advanced user, conventional CNC programming can be performed using G-Codes.
Programs can also be downloaded by DNC or input from a 'flash card' taken from a PC.
To which Booth adds: 'We also have a full CNC machine in the Combi K2 for repeat cycles that will have the respect of any engineering manager for the way it will perform in production.' Indeed, the College already has the support of 10 local companies taking up a 10 week introductory course to provide a sound understanding of CNC machining techniques and a course for manual machinists to upgrade to CNC.
According to Maria Hackett, head of school and job skills co-ordinator: 'The Dungannon area is the most active in Northern Ireland for engineering and in particular fabrication.
However, there is an increasing number of businesses that want to break into, or upgrade from manual to CNC machining and that is a prime area for us to satisfy with the new equipment.
With the addition of part time staff we will then introduce customised courses for local industry.' Modern apprenticeship courses are also being run on a day-release basis as well as full time BTEC National Diploma in Engineering.
And indeed, keen to catch the prospective student and with a view to nurturing an interest in engineering, the College has structured a series of two-day courses for local school children in conjunction with local businesses to give them an introduction to what engineering is all about.
As part of the two-day course, the children will be involved in projects such as making a CD holder and even be taken to a local engineering company to see real 'live' manufacturing.
Meanwhile, through the Women in Engineering WISE programme, European funding was gained by the College to train 20 women to NVQ Level 2 followed by placement with local employers.
With fresh ideas and schemes like these, Booth is adamant that selecting the right equipment was so crucial.
But as he maintains: 'We will need help with training and retraining as well as technical assistance, and part of our decision to buy the Colchester machines from Gillen Machine Tools is that we will be able to draw heavily on support in times of need.'
Twin-spindle CNC lathe is attractively priced
Equipped with C- and Y-axis plus 12 driven tools, a twin-spindle CNC slant bed lathe - built to Japanese quality - is being offered in the UK at at Taiwanese machine prices.
With C- and Y-axis plus 12 driven tools, the Taiwan Takisawa EX-910 twin-spindle CNC slant bed lathe available exclusively in the UK from Ward CNC of Sheffield offers an unmatched 'Japanese quality at a Taiwanese price' turning centre package. Having X-, Y-, Z-axis travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B-axis (right-hand spindle), the EX-910 features bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement the machine's maximum turning diameter and length capabilities of 340mm and 660mm. Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.
Driven tool speed is 4,000 rev/min from a 5.5kW motor.
Rapid traverse rates are quoted as 24m/min.
As standard, the heavy-duty cast iron construction is complemented by Fanuc 18i CNC, as well as four-track super rigid precision linear guideways and high-speed servo turret, auto tool setting arm, parts catcher and swarf conveyor.
Bar feed systems and collet chucks can be supplied as options.
With C- and Y-axis plus 12 driven tools, the Taiwan Takisawa EX-910 twin-spindle CNC slant bed lathe available exclusively in the UK from Ward CNC of Sheffield offers an unmatched 'Japanese quality at a Taiwanese price' turning centre package. Having X-, Y-, Z-axis travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B-axis (right-hand spindle), the EX-910 features bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement the machine's maximum turning diameter and length capabilities of 340mm and 660mm. Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.
Driven tool speed is 4,000 rev/min from a 5.5kW motor.
Rapid traverse rates are quoted as 24m/min.
As standard, the heavy-duty cast iron construction is complemented by Fanuc 18i CNC, as well as four-track super rigid precision linear guideways and high-speed servo turret, auto tool setting arm, parts catcher and swarf conveyor.
Bar feed systems and collet chucks can be supplied as options.
Thursday, May 25, 2006
CNC universal lathes' function options extended
High quality CNC universal lathes now have a choice of function expansion options including sub-spindle for two-sided machining, driven tools and Y-axis for eccentric boring and milling.
For metal removal performance, flexibility, speed and precision, the newly expandable DMG CTX-10 universal lathes are now unmatched in their price category. Already established as a range of universal lathes that represent good value for money, the CTX-10 Series is now available with a choice expansion options including sub-spindle for two-sided machining, driven tools and Y-axis for eccentric boring and milling. Not only do these allow the machine to grow to meet changing needs but also to be tailored to accommodate the complete machining of standard-sized parts.
Further options include the integrated spindle motor for fast acceleration and deceleration, digital drives and fast-indexing VDI servo turret - starting at 0.1 sec - with 12 tool stations.
These features enable idle times to be reduced by 25% leading to increased productivity and efficiency.
Customers can also specify a package for bar machining with an enlarged hollow clamping cylinder, steady-rest technology for shaft machining and workpiece pick-up units.
The easy integration of these elements is made possible by the build-quality of the CTX-10 machines and their sophisticated control technology.
All models have a 45 deg cast iron bed based on a rigid four-track design with linear roller guideways.
This combination provides the best operating conditions both the dynamic cross-slide and the hydraulically traversable tailstock.
Despite exceptionally quick positioning times, high rapid traverse speeds and dynamic digital drives the CTX-10 models can maintain the highest degree of accuracy thanks to direct measuring systems in the X and Z axes.
This eliminates the need for the time-consuming reference-point method.
For greater operator comfort customers can now also opt for the pivoting DMG SlimLinePanel with 15in TFT screen.
There are also three CNC control alternatives, the Siemens 840D with the latest ShopTurn 3D programming software, Heidenhain Plus IT with DINPlus (optionally TurnPlus), or the Fanuc 32i with Manual Guide i.
For metal removal performance, flexibility, speed and precision, the newly expandable DMG CTX-10 universal lathes are now unmatched in their price category. Already established as a range of universal lathes that represent good value for money, the CTX-10 Series is now available with a choice expansion options including sub-spindle for two-sided machining, driven tools and Y-axis for eccentric boring and milling. Not only do these allow the machine to grow to meet changing needs but also to be tailored to accommodate the complete machining of standard-sized parts.
Further options include the integrated spindle motor for fast acceleration and deceleration, digital drives and fast-indexing VDI servo turret - starting at 0.1 sec - with 12 tool stations.
These features enable idle times to be reduced by 25% leading to increased productivity and efficiency.
Customers can also specify a package for bar machining with an enlarged hollow clamping cylinder, steady-rest technology for shaft machining and workpiece pick-up units.
The easy integration of these elements is made possible by the build-quality of the CTX-10 machines and their sophisticated control technology.
All models have a 45 deg cast iron bed based on a rigid four-track design with linear roller guideways.
This combination provides the best operating conditions both the dynamic cross-slide and the hydraulically traversable tailstock.
Despite exceptionally quick positioning times, high rapid traverse speeds and dynamic digital drives the CTX-10 models can maintain the highest degree of accuracy thanks to direct measuring systems in the X and Z axes.
This eliminates the need for the time-consuming reference-point method.
For greater operator comfort customers can now also opt for the pivoting DMG SlimLinePanel with 15in TFT screen.
There are also three CNC control alternatives, the Siemens 840D with the latest ShopTurn 3D programming software, Heidenhain Plus IT with DINPlus (optionally TurnPlus), or the Fanuc 32i with Manual Guide i.
Long bed CNC lathe offers heavy duty turning
Heavy duty, long bed universal CNC lathe offers users an exceptional combination of turning capacity and capability at an unrivalled cost.
The Taiwan Takisawa EX-122 heavy-duty, long bed universal CNC lathe available from Ward CNC of Sheffield offers users an exceptional combination of turning capacity and capability at an unrivalled cost. With maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min, the machine's cast iron slant bed construction combines with extra heavy duty linear guideway technology to provide an exceptional performance 'Japanese quality at Taiwanese prices' package. Part of Ward CNC's Taiwan Takisawa portfolio, the EX-122 has a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330mm and 1650mm, respectively, and a 200mm spindle bore.
Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.
Auto tool setting arm, bar feed interface and swarf conveyor are supplied as standard; bar feed systems and steady rests are optional extras.
The Taiwan Takisawa EX-122 heavy-duty, long bed universal CNC lathe available from Ward CNC of Sheffield offers users an exceptional combination of turning capacity and capability at an unrivalled cost. With maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min, the machine's cast iron slant bed construction combines with extra heavy duty linear guideway technology to provide an exceptional performance 'Japanese quality at Taiwanese prices' package. Part of Ward CNC's Taiwan Takisawa portfolio, the EX-122 has a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330mm and 1650mm, respectively, and a 200mm spindle bore.
Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.
Auto tool setting arm, bar feed interface and swarf conveyor are supplied as standard; bar feed systems and steady rests are optional extras.
Sunday, May 21, 2006
Subcontractor adds CNC turning to up capacity
When a Welsh subcontract machining company wants to extend capacity, it invests in the latest CNC turning centres, lathes and feeding equipment rather than expand working hours or add shifts.
As the third generation managing director of family-owned TS Henderson located at the foot of the Brecon Beacons, UK, Rob Henderson maintains: 'Most people arrive here thinking they will find a field of sheep, a cow shed and tractors, and they are actually quite surprised - and naturally relieved - when they see our 15,000ft2 factory, our portfolio of over 20 high-tech CNC machines and, in particular, how we utilise our nine Colchester CNC Tornado two- and three-axis turning machines.' Henderson never fails to be amused by the expectations of potential customers when they arrive at the Hay on Wye (Herefordshire) based specialist supplier of high-quality sub-contract parts to, for example, companies in the automotive, electronics, lifting gear, marine and motor sport sectors. While all these customers are based in the UK, he suggests that 80% of the parts he supplies are eventually destined for export. Henderson is very serious when it comes to making the most of his high-tech CNC machining technology to satisfy customer demands for a wide variety of prismatic and shaft-type components in varying batch quantities.
Most of the company's turning work is produced on the Tornado machines - a mixture of two- and three-axis Tornado 80, 90, 220M and the latest T6M models that have been installed progressively since 1996.
All equipped with bar feeders for unmanned, automatic running, the Tornados have consistently proved to be reliable generating high returns on their investment in the production of all manner of parts in all materials - including the often problematic 316 stainless steel - an important factor in his continual investment in the marque against the demands of his order book.
He says: 'In addition to offering the right specification at the right price, the Tornado machines bought from Colchestersales have always been supported with excellent back-up.
This is crucial to us.
And if we do have a problem, with either the machine or programming, for example, we can get superb 'phone support - which means they're not automatically sending out an engineer followed by an invoice.
Customer service on this level means a lot to me, and it gives me great confidence when I need to invest,' he insists.
Henderson's capital expenditure philosophy is equally as pragmatic: to meet any sustained hike in demand, he simply buys additional machines rather than extend the working hours; even though the company's single day shift for 5.1/2 days a week is complemented by the extended running capabilities of the Tornados via bar feed systems.
Currently employing 28 people he outlines: 'If we added another shift, i e, a night shift, we would effectively have to almost double the workforce but you have to be mindful of the effect of a quiet period which could lead to having to lay people off.
For us, installing another machine is a much simpler solution.
Machines do not go to the dentist, they do not have personal problems, and if the workload does dip, then they can be switched off.' Thankfully, he reflects, it has been some time since any machine has stood dormant through lack of work and, in fact, increasing demand - especially for turn/milled parts - during the past two years has spurred the BS EN ISO 9002-accredited company to invest in three-axis driven tool turning cycles from Colchestersales.
It has installed both the Tornado 220M and latest T6M models during 2005 to complement the six Tornado 80 models and a single Tornado 90 two-axis machine.
These machines complement six machining centres and an impressive multi-spindle turning, milling, grinding, thread rolling and centreless grinding capacity.
Specifically designed to combine previous separate operations into a single cycle, TS Henderson has found increased productivity has been achieved at an unrivalled cost-to-performance ratio.
The latest Tornado T6M has a 54mm bar capacity, offers a swing over the bed of 440mm and maximum turning diameters and lengths of 200mm and 450mm, respectively.
With a 15kW spindle motor providing spindle speeds of 6,000 rev/min, coupled with rapid traverse rates of 25m/min and 30m/min in the X and Z axes, for the 12 driven tool VDI 30 turret, the machine has satisfied every demand that Henderson has so far presented it with.
Workpieces successfully machined in a single cycle sequence of turning and milling extend from the complex to the fairly simple, including filter adaptors for the automotive sector and even single parts for steam engines.
In addition to highlighting the machine's impressive build qualities as enabling consistent performance, the Duo-stable construction that uses an inert concrete composite encapsulated in a heavy-duty fabrication and reinforced with a network of ribs for excellent thermal and dynamic stability - Rob Henderson also points to the T6M's Fanuc 21i control system as being particularly beneficial.
The CNC includes the Colchestersales-developed Manual Guide - i conversational programming technology.
This has high level graphics support giving full simulation and verification of any cutting cycle in both 2-D and 3-D plus the ability to manipulate machining operations so that the part and toolpaths can be viewed from any angle.
Not only does this system interface with all major CAD/CAM systems but it also makes programming of single part cycles extremely effective, quick and simple.
Equal praise is also bestowed upon the accompanying ColCAM off-line programming software: 'Once a job is programmed, the cycles are easy to follow with 3D graphics showing the tool tip shape, and axial and radial drilling and milling tool paths clearly depicted,' he says.
Commenting on the effectiveness of 'upgrading' to three-axis machining, Henderson does not mince his words: 'I cannot say that we always achieve fantastic reductions in cycle times on multi-operation work through one-hit machining,' he comments.
'But the real benefit is the reduction in the number of operations, setting and inspection which reflects on reduced lead times and the associated labour resource of transferring parts to, say, a machining centre or pillar drill.' This down-to-earth business philosophy is applied to every aspect of the company - for example, almost GBP 100,000 of round steel/stainless bar, as well as brass, bronze, aluminium and Nylon, is maintained as a key factor to provide immediate response to all customer demands, to complement the usual just-in-time delivery schedules.
And in terms of customer service, it has not been unknown for the TS Henderson delivery van to be despatched to a distant customer with just a handful of parts on board, to meet a particular request.
'Sub-contractors are service providers,' Henderson concludes, 'You need the right equipment to perform the task which we have managed to achieve but if you don't provide a service you will not stay in business.
As the third generation managing director of family-owned TS Henderson located at the foot of the Brecon Beacons, UK, Rob Henderson maintains: 'Most people arrive here thinking they will find a field of sheep, a cow shed and tractors, and they are actually quite surprised - and naturally relieved - when they see our 15,000ft2 factory, our portfolio of over 20 high-tech CNC machines and, in particular, how we utilise our nine Colchester CNC Tornado two- and three-axis turning machines.' Henderson never fails to be amused by the expectations of potential customers when they arrive at the Hay on Wye (Herefordshire) based specialist supplier of high-quality sub-contract parts to, for example, companies in the automotive, electronics, lifting gear, marine and motor sport sectors. While all these customers are based in the UK, he suggests that 80% of the parts he supplies are eventually destined for export. Henderson is very serious when it comes to making the most of his high-tech CNC machining technology to satisfy customer demands for a wide variety of prismatic and shaft-type components in varying batch quantities.
Most of the company's turning work is produced on the Tornado machines - a mixture of two- and three-axis Tornado 80, 90, 220M and the latest T6M models that have been installed progressively since 1996.
All equipped with bar feeders for unmanned, automatic running, the Tornados have consistently proved to be reliable generating high returns on their investment in the production of all manner of parts in all materials - including the often problematic 316 stainless steel - an important factor in his continual investment in the marque against the demands of his order book.
He says: 'In addition to offering the right specification at the right price, the Tornado machines bought from Colchestersales have always been supported with excellent back-up.
This is crucial to us.
And if we do have a problem, with either the machine or programming, for example, we can get superb 'phone support - which means they're not automatically sending out an engineer followed by an invoice.
Customer service on this level means a lot to me, and it gives me great confidence when I need to invest,' he insists.
Henderson's capital expenditure philosophy is equally as pragmatic: to meet any sustained hike in demand, he simply buys additional machines rather than extend the working hours; even though the company's single day shift for 5.1/2 days a week is complemented by the extended running capabilities of the Tornados via bar feed systems.
Currently employing 28 people he outlines: 'If we added another shift, i e, a night shift, we would effectively have to almost double the workforce but you have to be mindful of the effect of a quiet period which could lead to having to lay people off.
For us, installing another machine is a much simpler solution.
Machines do not go to the dentist, they do not have personal problems, and if the workload does dip, then they can be switched off.' Thankfully, he reflects, it has been some time since any machine has stood dormant through lack of work and, in fact, increasing demand - especially for turn/milled parts - during the past two years has spurred the BS EN ISO 9002-accredited company to invest in three-axis driven tool turning cycles from Colchestersales.
It has installed both the Tornado 220M and latest T6M models during 2005 to complement the six Tornado 80 models and a single Tornado 90 two-axis machine.
These machines complement six machining centres and an impressive multi-spindle turning, milling, grinding, thread rolling and centreless grinding capacity.
Specifically designed to combine previous separate operations into a single cycle, TS Henderson has found increased productivity has been achieved at an unrivalled cost-to-performance ratio.
The latest Tornado T6M has a 54mm bar capacity, offers a swing over the bed of 440mm and maximum turning diameters and lengths of 200mm and 450mm, respectively.
With a 15kW spindle motor providing spindle speeds of 6,000 rev/min, coupled with rapid traverse rates of 25m/min and 30m/min in the X and Z axes, for the 12 driven tool VDI 30 turret, the machine has satisfied every demand that Henderson has so far presented it with.
Workpieces successfully machined in a single cycle sequence of turning and milling extend from the complex to the fairly simple, including filter adaptors for the automotive sector and even single parts for steam engines.
In addition to highlighting the machine's impressive build qualities as enabling consistent performance, the Duo-stable construction that uses an inert concrete composite encapsulated in a heavy-duty fabrication and reinforced with a network of ribs for excellent thermal and dynamic stability - Rob Henderson also points to the T6M's Fanuc 21i control system as being particularly beneficial.
The CNC includes the Colchestersales-developed Manual Guide - i conversational programming technology.
This has high level graphics support giving full simulation and verification of any cutting cycle in both 2-D and 3-D plus the ability to manipulate machining operations so that the part and toolpaths can be viewed from any angle.
Not only does this system interface with all major CAD/CAM systems but it also makes programming of single part cycles extremely effective, quick and simple.
Equal praise is also bestowed upon the accompanying ColCAM off-line programming software: 'Once a job is programmed, the cycles are easy to follow with 3D graphics showing the tool tip shape, and axial and radial drilling and milling tool paths clearly depicted,' he says.
Commenting on the effectiveness of 'upgrading' to three-axis machining, Henderson does not mince his words: 'I cannot say that we always achieve fantastic reductions in cycle times on multi-operation work through one-hit machining,' he comments.
'But the real benefit is the reduction in the number of operations, setting and inspection which reflects on reduced lead times and the associated labour resource of transferring parts to, say, a machining centre or pillar drill.' This down-to-earth business philosophy is applied to every aspect of the company - for example, almost GBP 100,000 of round steel/stainless bar, as well as brass, bronze, aluminium and Nylon, is maintained as a key factor to provide immediate response to all customer demands, to complement the usual just-in-time delivery schedules.
And in terms of customer service, it has not been unknown for the TS Henderson delivery van to be despatched to a distant customer with just a handful of parts on board, to meet a particular request.
'Sub-contractors are service providers,' Henderson concludes, 'You need the right equipment to perform the task which we have managed to achieve but if you don't provide a service you will not stay in business.
CNC shaft lathe reduces loading and set-up time
Purpose-built for automated, high-precision, internal and external machining of large shafts and pipes, CNC shaft lathes has automatic chucking and steadying, for rapid loading and set-up.
Classic lathe maker Dean, Smith and Grace of Keighley, West Yorkshire, UK, has received the first order for one of its new breed of CNC shaft lathes - purpose-built for fully automated, high-precision, internal and external machining of large shafts and pipes. Designated 'SE' (Special Equipment), the first in the range, set to be delivered in February to a Northeast UK-based manufacturer of mechanical excavator rams, is a 2817 x 150 model. It incorporates a 4000mm length bed, Fanuc 18i control - and fully automated chucking and steadying equipment, for rapid loading and set-up.
By fully automating the set-up process, large and unwieldy pipes or shafts can be quickly loaded and set-up with just one operator, at a stroke slashing floor-to-floor times for what has historically been a difficult and labour-intensive task.
Providing the quick loading and set-up is a fully automatic SMW KCNS 400 hydraulic, quick release, chucking system; complemented by an SMW type SLU-Z-4 three-point roller steady with mechanical positioning.
The three-point roller steady can traverse the full length of the bed - under operator's control or automatically - to find the optimum position of support, while hydraulically operated jaws clamp to the workpiece or retract as required.
The chuck and steady work in conjunction with an automatic tailstock, designed and manufactured 'in-house' by Dean, Smith and Grace.
The tailstock utilises hydraulic power and the lathe's rack and pinion drive to automatically position at pre-set locations programmed by the operator.
Other features of the 'SE' include: Sauter 12-station auto indexing VDI turret, slat-type swarf conveyor, Fanuc digital motors, precision ball screws and Vogel/Sterling automatic lubrication system - though customers can specify the control/equipment of their choice.
Dean, Smith and Grace managing director, Nigel Grainger, comments: 'Few lathe manufacturers in the world - if any - have a machine range on the market that addresses the 'pipe' lathe sector as comprehensively as our new 'SE' range.
By keeping costs down, building on a proven build spec, and addressing the requirements of rapid loading and set-up using a single operator, this new lathe offers up new standards of cost efficiency and productivity for a wide range of industries.' A significant feature of all Dean, Smith and Grace production, including the new 'SE', is the capability not only to supply 'off-the-peg' lathes, hand-built to the highest specifications, but also individual engineered solutions tailored to the customer's needs.
Thus, Dean, Smith and Grace engineers and designers are more than happy to discuss application requirements before the build phase begins.
Classic lathe maker Dean, Smith and Grace of Keighley, West Yorkshire, UK, has received the first order for one of its new breed of CNC shaft lathes - purpose-built for fully automated, high-precision, internal and external machining of large shafts and pipes. Designated 'SE' (Special Equipment), the first in the range, set to be delivered in February to a Northeast UK-based manufacturer of mechanical excavator rams, is a 2817 x 150 model. It incorporates a 4000mm length bed, Fanuc 18i control - and fully automated chucking and steadying equipment, for rapid loading and set-up.
By fully automating the set-up process, large and unwieldy pipes or shafts can be quickly loaded and set-up with just one operator, at a stroke slashing floor-to-floor times for what has historically been a difficult and labour-intensive task.
Providing the quick loading and set-up is a fully automatic SMW KCNS 400 hydraulic, quick release, chucking system; complemented by an SMW type SLU-Z-4 three-point roller steady with mechanical positioning.
The three-point roller steady can traverse the full length of the bed - under operator's control or automatically - to find the optimum position of support, while hydraulically operated jaws clamp to the workpiece or retract as required.
The chuck and steady work in conjunction with an automatic tailstock, designed and manufactured 'in-house' by Dean, Smith and Grace.
The tailstock utilises hydraulic power and the lathe's rack and pinion drive to automatically position at pre-set locations programmed by the operator.
Other features of the 'SE' include: Sauter 12-station auto indexing VDI turret, slat-type swarf conveyor, Fanuc digital motors, precision ball screws and Vogel/Sterling automatic lubrication system - though customers can specify the control/equipment of their choice.
Dean, Smith and Grace managing director, Nigel Grainger, comments: 'Few lathe manufacturers in the world - if any - have a machine range on the market that addresses the 'pipe' lathe sector as comprehensively as our new 'SE' range.
By keeping costs down, building on a proven build spec, and addressing the requirements of rapid loading and set-up using a single operator, this new lathe offers up new standards of cost efficiency and productivity for a wide range of industries.' A significant feature of all Dean, Smith and Grace production, including the new 'SE', is the capability not only to supply 'off-the-peg' lathes, hand-built to the highest specifications, but also individual engineered solutions tailored to the customer's needs.
Thus, Dean, Smith and Grace engineers and designers are more than happy to discuss application requirements before the build phase begins.
Wednesday, May 17, 2006
CNC lathes have high specification
Five high-specification yet cost-competitive CNC turning machines to be shown at MACH 2006 - including high capacity, long bed types - suit different production demands - and budgets.
The MACH display being mounted by Ward CNC of Sheffield will include five high-specification yet cost-competitive turning machines to suit the production demands - and budgets - of companies of every size in all industry sectors. Featuring four Takisawa Taiwan lathes that boast 'Japanese quality at Taiwanese prices', plus a heavyweight 4m bed Hankook machine, the machines will complement Ward CNC's MACH display of Hartford machining centres that, like the Takisawa Taiwan portfolio, are hard to match in terms of cost-to-performance ratio. Takisawa Taiwan machines utilise a special one-piece, thermally balanced bed that promotes powerful and stable operation, coupled with four-track super rigid precision linear guideways and high-speed servo turrets.
Fanuc 18i or 21iT CNC feature as standard.
With C and Y axes plus 12 driven tools, the Takisawa Taiwan EX-910 twin-spindle CNC slant bed lathe has X, Y, Z axes travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B-axis (right-hand spindle).
It accommodates bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement maximum turning diameter and length capabilities of 340mm and 660mm.
The main spindle incorporates oil-cooled Fanuc built-in motor providing exceptional performance for turning and C-axis operations.
Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.
Driven tool speed is 4,000 rev/min from a 5.5kW motor.
Rapid traverse rates are 24m/min.
As standard, the machine is supplied with auto tool setting arm, parts catcher and swarf conveyor.
Bar feed systems and collet chucks are options.
With a swing over the bed of 400mm, the Takisawa Taiwan EX-108 has a crosslide travel of 320mm and a between centres distance of 645mm.
Standard turning diameter is 216mm, and with a 203mm chuck the machine has a maximum turning diameter and length of 320mm and 530mm, respectively.
Bar capacity is 52mm and spindle speeds range from 60-4,000 rev/min (7.5/11kW) for the 12-tool turret machine.
Auto tool setting arm, parts catcher, swarf conveyor and programmable quill tailstock are standard; collet chucks and bar feed systems are options.
Two Takisawa Taiwan heavy-duty CNC lathes will be on show - the EX-122 and the TW 46.
Of cast iron slant bed construction combined with extra heavy duty linear guideway technology, the long bed EX-122 universal has maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min.
The EX-122/H variant offers a 30/37kW main motor, which coupled with the standard two-range geared headstock offers excellent power and torque capabilities.
The EX-122 and EX-122/H have a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330 mm and 1650mm, respectively, and a 200mm spindle bore.
Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.
Auto tool setting arm, bar feed interface and swarf conveyor are supplied as standard; bar feed systems and steady rests are optional extras.
Based on similar construction principles, the Takisawa Taiwan TW 46 features a 760mm swing over the bed and maximum turning diameters and lengths of 460mm and 910mm, respectively.
With 250mm in the X-axis and 980mm in Z, the 91mm spindle bore machine features a 318mm chuck (15in) as standard and spindle speeds of 25-2,500 rev/min and rapid traverses of 20m/min.
With a 4m bed, the Hankook Protec 9NC two-axis horizontal 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 254mm) twin chuck machine has a 950mm swing over bed, 630mm over carriage and 4000mm between centres (options up to 8000mm available).
It features a Fanuc 21i-T CNC, which offers semi-CNC manual guidance and teach facility.
At MACH, Ward CNC will also have details available of its extensive ranges of Soraluce milling, Toshulin VTL and Union milling and boring centres.
The MACH display being mounted by Ward CNC of Sheffield will include five high-specification yet cost-competitive turning machines to suit the production demands - and budgets - of companies of every size in all industry sectors. Featuring four Takisawa Taiwan lathes that boast 'Japanese quality at Taiwanese prices', plus a heavyweight 4m bed Hankook machine, the machines will complement Ward CNC's MACH display of Hartford machining centres that, like the Takisawa Taiwan portfolio, are hard to match in terms of cost-to-performance ratio. Takisawa Taiwan machines utilise a special one-piece, thermally balanced bed that promotes powerful and stable operation, coupled with four-track super rigid precision linear guideways and high-speed servo turrets.
Fanuc 18i or 21iT CNC feature as standard.
With C and Y axes plus 12 driven tools, the Takisawa Taiwan EX-910 twin-spindle CNC slant bed lathe has X, Y, Z axes travels of 245mm, 160mm and 710mm, as well as 710mm travel in the B-axis (right-hand spindle).
It accommodates bar capacities of 75mm and 52mm (left- and right-hand spindles, respectively) to complement maximum turning diameter and length capabilities of 340mm and 660mm.
The main spindle incorporates oil-cooled Fanuc built-in motor providing exceptional performance for turning and C-axis operations.
Swing over the bed is 680mm, chuck size is 255mm on both spindles, and spindle speeds are up to 3,500 rev/min from the 22/18.5kW motors on both spindles.
Driven tool speed is 4,000 rev/min from a 5.5kW motor.
Rapid traverse rates are 24m/min.
As standard, the machine is supplied with auto tool setting arm, parts catcher and swarf conveyor.
Bar feed systems and collet chucks are options.
With a swing over the bed of 400mm, the Takisawa Taiwan EX-108 has a crosslide travel of 320mm and a between centres distance of 645mm.
Standard turning diameter is 216mm, and with a 203mm chuck the machine has a maximum turning diameter and length of 320mm and 530mm, respectively.
Bar capacity is 52mm and spindle speeds range from 60-4,000 rev/min (7.5/11kW) for the 12-tool turret machine.
Auto tool setting arm, parts catcher, swarf conveyor and programmable quill tailstock are standard; collet chucks and bar feed systems are options.
Two Takisawa Taiwan heavy-duty CNC lathes will be on show - the EX-122 and the TW 46.
Of cast iron slant bed construction combined with extra heavy duty linear guideway technology, the long bed EX-122 universal has maximum turning lengths and diameters of 1650mm and 610mm, respectively, coupled with a 22/26kW motor producing spindle speeds from 12 to 1,200 rev/min.
The EX-122/H variant offers a 30/37kW main motor, which coupled with the standard two-range geared headstock offers excellent power and torque capabilities.
The EX-122 and EX-122/H have a swing over the bed of 910mm and 560mm over the crosslide, as well as X and Z axes strokes of 330 mm and 1650mm, respectively, and a 200mm spindle bore.
Rapid traverse rates are up to 24m/min and the Fanuc 21iT CNC complements the 10-station tool turret to offer users a multitude of machining alternatives on a machine that is fitted with a 533mm (21in) three-jaw hydraulic chuck as standard.
Auto tool setting arm, bar feed interface and swarf conveyor are supplied as standard; bar feed systems and steady rests are optional extras.
Based on similar construction principles, the Takisawa Taiwan TW 46 features a 760mm swing over the bed and maximum turning diameters and lengths of 460mm and 910mm, respectively.
With 250mm in the X-axis and 980mm in Z, the 91mm spindle bore machine features a 318mm chuck (15in) as standard and spindle speeds of 25-2,500 rev/min and rapid traverses of 20m/min.
With a 4m bed, the Hankook Protec 9NC two-axis horizontal 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 254mm) twin chuck machine has a 950mm swing over bed, 630mm over carriage and 4000mm between centres (options up to 8000mm available).
It features a Fanuc 21i-T CNC, which offers semi-CNC manual guidance and teach facility.
At MACH, Ward CNC will also have details available of its extensive ranges of Soraluce milling, Toshulin VTL and Union milling and boring centres.
CNC lathe has NC electric tailstock
Latest production CNC turning machine features a NC electric tailstock that delivers quick set-up with no manual intervention.
Quick Turn Nexus - the solution to the problem The Quick Turn Nexus series of turning centres from Yamazaki Mazak combines those crucial elements required in today's modern manufacturing environment - namely advanced technology, productivity and value for money. In designing the Quick Turn Nexus range Mazak completed a thorough review of the basic machine components and used state-of-the-art design technology to arrive at a range of turning centres ideally suited to meet the production needs of businesses large and small. At MACH 2006 the range will be represented by the recently introduced Quick Turn Nexus 350MY.
This single 30kW/3300 rev/min spindle machine has a machining capacity of 420mm diameter by up to 1538mm long.
It also benefits from the inclusion of a NC electric tailstock that delivers quick set-up with no manual intervention.
The tailstock provides accurate support even for components that can only be supported by low-thrust force.
Positioning and thrust force is achieved using servo motors and are programmable.
Each position in the 12 station drum-type turret can be used for rotary tools, which are driven by a 7.5kW/4000 rev/min motor.
The versatility of the QTN350MY is complemented by the addition of a 150mm Y-axis, further expanding the machine's possible application areas.
Power is matched by agility, with the X and Z axes having rapid traverse rates of 30m/min and 25m/min respectively.
The resulting fast, vibration-free acceleration/deceleration is due to the use of high-gain servo-control and high-power AC servo motors.
Control is provided by the Mazatrol Fusion 640T Nexus CNC unit that features the easy-to-use Mazatrol conversational programming format.
As a result programming time and program length are considerably reduced and editing of existing programs is simplified.
Additional benefits of the Mazatrol Fusion control are its ability to accept modification of programs with minimum editing, cutting conditions are determined automatically by the automatic cutting condition function, edited cutting conditions are stored and recalled when the same material is used again.
Quick Turn Nexus - the solution to the problem The Quick Turn Nexus series of turning centres from Yamazaki Mazak combines those crucial elements required in today's modern manufacturing environment - namely advanced technology, productivity and value for money. In designing the Quick Turn Nexus range Mazak completed a thorough review of the basic machine components and used state-of-the-art design technology to arrive at a range of turning centres ideally suited to meet the production needs of businesses large and small. At MACH 2006 the range will be represented by the recently introduced Quick Turn Nexus 350MY.
This single 30kW/3300 rev/min spindle machine has a machining capacity of 420mm diameter by up to 1538mm long.
It also benefits from the inclusion of a NC electric tailstock that delivers quick set-up with no manual intervention.
The tailstock provides accurate support even for components that can only be supported by low-thrust force.
Positioning and thrust force is achieved using servo motors and are programmable.
Each position in the 12 station drum-type turret can be used for rotary tools, which are driven by a 7.5kW/4000 rev/min motor.
The versatility of the QTN350MY is complemented by the addition of a 150mm Y-axis, further expanding the machine's possible application areas.
Power is matched by agility, with the X and Z axes having rapid traverse rates of 30m/min and 25m/min respectively.
The resulting fast, vibration-free acceleration/deceleration is due to the use of high-gain servo-control and high-power AC servo motors.
Control is provided by the Mazatrol Fusion 640T Nexus CNC unit that features the easy-to-use Mazatrol conversational programming format.
As a result programming time and program length are considerably reduced and editing of existing programs is simplified.
Additional benefits of the Mazatrol Fusion control are its ability to accept modification of programs with minimum editing, cutting conditions are determined automatically by the automatic cutting condition function, edited cutting conditions are stored and recalled when the same material is used again.
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