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.
Saturday, June 03, 2006
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.
Thursday, May 11, 2006
Heavy duty CNC lathes can be customised
A range of heavy duty, CNC, flat-bed lathes include one customised with a gap bed facility, allowing an exceptionally large swing of 865mm and is fitted with Siemens 810D CNC.
Preparing for its first MACH exhibition since its resurgence as a major power in the UK machine tool manufacturing industry, classic lathe maker Dean, Smith and Grace of Keighley, West Yorkshire, exhibits two examples from its '2000' Series range of heavy duty, CNC, flat-bed lathes. The Type 2413 x 50 (610mm swing over bed/330mm swing over saddle x 1270mm between centres) Gap Bed lathe on show has been bespoke engineered for a customer and is the eighteenth consecutive Dean, Smith and Grace CNC lathe that the company has purchased. Precisely tailored for the customer's application, the 'MACH' show machine features a gap bed facility, allowing an exceptionally large swing of 865mm (34in), an integral side discharge conveyor and the customer's control of choice, Siemens 810D CNC.
Standard features include: Sauter eight-station turret to accept 50mm VDI tooling; 26kW spindle motor; three jaw precision chuck with serrated base jaws; induction hardened bed built to BS 2656 alignment standards; Favretto ground bed ways; high performance digital servos; precision ballscrews on rigid bearings; automatic lubrication system; variable spindle speed and fully guarded operator protection systems.
Optional productivity enhancements available for this machine include: suitable tooling packages complete with 50mm VDI tool holders; parts catcher; 630mm hydraulic closed centre power chuck complete with closed centre cylinder fitted with 3/32in x 90 deg serrated base; and software upgrade to PCU50 10GB c/w wireless compatible software.
Renowned for their accuracy and rigidity and ideal for close tolerance 'one-offs' and prototypes, Dean, Smith and Grace lathes are equally adept in the production of small-to-medium size batches.
To reinforce this concept, Dean, Smith and Grace will exhibit a Type 2110 x 60 (533mm swing over bed/254mm swing over saddle x 1500mm between centres) CNC lathe, again bespoke engineered for a customer's application - in this case the volume production of bearings in composite materials.
For optimum cutting efficiency the lathe utilises a specially designed headstock with a larger spindle than the norm.
It is equipped with a bespoke pneumatic single bar feed system which utilises the spindle bore as the cylinder, interlocked to a pushrod on the rear of the spindle and a 180mm SMW collet chuck.
The lathe is fitted with the latest Fanuc SVPM single drive module Oi-TC control with 180mm (7.2in) LCD screen.
The Dean, Smith and Grace heavy duty range includes the '2000', '3000', '4000' and '5000' Series of flat bed, CNC lathes.
The 2000 Series is available with a swing of 610-762mm; the 3000 Series a swing of 810-1000mm; the 4000 Series a swing of 1000-1200mm; and the 5000 Series a swing of 1200-1500mm.
Complementing its heavy duty ranges Dean, Smith and Grace continues to produce its famous large capacity Type 25P and 30P dual-manual/CNC lathes.
Equipped with 276 and 381mm spindle bores, the Type 25P and Type 30P 'pipe' lathes remain a firm favourite with oilfield equipment manufacturers.
Each features powerful drive motors which complement four manually selected gear ranges to provide exceptionally large torque at very low speeds, while bed rigidity and long life is probably the best in the business through the use of a heavily ribbed casting and the outstanding design of the carburised, and Reishauer ground, gears.
In addition, DSG is currently developing a new range of lathes with a spindle diameter of 535mm.
Dean, Smith and Grace also retains its unrivalled capabilities in rebuilding lathes, milling machines and other precision machine tools to 'as new' standards and equipped with the very latest CNC control system of customer choice.
High precision slideway grinding facilities guarantee superb accuracy and surface finish, while a Dean, Smith and Grace rebuild remains better value than many new machines available on the market today.
Complementing its abilities to supply 'off-the-peg' CNC and manual lathes, hand-built to the highest specifications, Dean, Smith and Grace can also build individual lathes tailored to the customer's precise dimensions and requirements.
Dean, Smith and Grace welcomes the chance to discuss customers' specific applications at the MACH exhibition - and to offer the bespoke engineered, production efficient solutions, that the company can provide.
Preparing for its first MACH exhibition since its resurgence as a major power in the UK machine tool manufacturing industry, classic lathe maker Dean, Smith and Grace of Keighley, West Yorkshire, exhibits two examples from its '2000' Series range of heavy duty, CNC, flat-bed lathes. The Type 2413 x 50 (610mm swing over bed/330mm swing over saddle x 1270mm between centres) Gap Bed lathe on show has been bespoke engineered for a customer and is the eighteenth consecutive Dean, Smith and Grace CNC lathe that the company has purchased. Precisely tailored for the customer's application, the 'MACH' show machine features a gap bed facility, allowing an exceptionally large swing of 865mm (34in), an integral side discharge conveyor and the customer's control of choice, Siemens 810D CNC.
Standard features include: Sauter eight-station turret to accept 50mm VDI tooling; 26kW spindle motor; three jaw precision chuck with serrated base jaws; induction hardened bed built to BS 2656 alignment standards; Favretto ground bed ways; high performance digital servos; precision ballscrews on rigid bearings; automatic lubrication system; variable spindle speed and fully guarded operator protection systems.
Optional productivity enhancements available for this machine include: suitable tooling packages complete with 50mm VDI tool holders; parts catcher; 630mm hydraulic closed centre power chuck complete with closed centre cylinder fitted with 3/32in x 90 deg serrated base; and software upgrade to PCU50 10GB c/w wireless compatible software.
Renowned for their accuracy and rigidity and ideal for close tolerance 'one-offs' and prototypes, Dean, Smith and Grace lathes are equally adept in the production of small-to-medium size batches.
To reinforce this concept, Dean, Smith and Grace will exhibit a Type 2110 x 60 (533mm swing over bed/254mm swing over saddle x 1500mm between centres) CNC lathe, again bespoke engineered for a customer's application - in this case the volume production of bearings in composite materials.
For optimum cutting efficiency the lathe utilises a specially designed headstock with a larger spindle than the norm.
It is equipped with a bespoke pneumatic single bar feed system which utilises the spindle bore as the cylinder, interlocked to a pushrod on the rear of the spindle and a 180mm SMW collet chuck.
The lathe is fitted with the latest Fanuc SVPM single drive module Oi-TC control with 180mm (7.2in) LCD screen.
The Dean, Smith and Grace heavy duty range includes the '2000', '3000', '4000' and '5000' Series of flat bed, CNC lathes.
The 2000 Series is available with a swing of 610-762mm; the 3000 Series a swing of 810-1000mm; the 4000 Series a swing of 1000-1200mm; and the 5000 Series a swing of 1200-1500mm.
Complementing its heavy duty ranges Dean, Smith and Grace continues to produce its famous large capacity Type 25P and 30P dual-manual/CNC lathes.
Equipped with 276 and 381mm spindle bores, the Type 25P and Type 30P 'pipe' lathes remain a firm favourite with oilfield equipment manufacturers.
Each features powerful drive motors which complement four manually selected gear ranges to provide exceptionally large torque at very low speeds, while bed rigidity and long life is probably the best in the business through the use of a heavily ribbed casting and the outstanding design of the carburised, and Reishauer ground, gears.
In addition, DSG is currently developing a new range of lathes with a spindle diameter of 535mm.
Dean, Smith and Grace also retains its unrivalled capabilities in rebuilding lathes, milling machines and other precision machine tools to 'as new' standards and equipped with the very latest CNC control system of customer choice.
High precision slideway grinding facilities guarantee superb accuracy and surface finish, while a Dean, Smith and Grace rebuild remains better value than many new machines available on the market today.
Complementing its abilities to supply 'off-the-peg' CNC and manual lathes, hand-built to the highest specifications, Dean, Smith and Grace can also build individual lathes tailored to the customer's precise dimensions and requirements.
Dean, Smith and Grace welcomes the chance to discuss customers' specific applications at the MACH exhibition - and to offer the bespoke engineered, production efficient solutions, that the company can provide.
CNC lathe company includes VMCs in packages
Colchestersales (UK) is to market the Richmond vertical machining centres as part of its high technology mill/turn machining packages involving the Tornado, Combi and MultiTurn.
Colchestersales (UK) based in Heckmondwike, West Yorkshire, is to market the latest advanced and high specification range of Richmond vertical machining centres as part of its high technology machining packages involving the Colchester Lathe range of Tornado, Combi and MultiTurn. The machine range is also sold by 600 Centre of Shepshed near Loughborough, UK, where the Midlands-based Colchestersales Technology Centre is also established. Explained Colchester Lathe director Mike Berry: 'Both 600 Centre and Colchestersales (UK) are putting together packages of machines to customers that want to deal with a single supplier that has a known history and good aftersales support, so it was logical to offer the Richmond as a 600 Group product to both operations.' The Richmond range spans a compact 500L with travels of 510mm in X, 410mm in Y and 460mm in Z with 12 or 20 tools, 5.5kW or 7.5kW spindle motor and options of 8,000, 10,000 or 12,000 rev/min to the top of the range VMC 1600S.
This machine weighs a massive 14 tonnes and has a BT50, spindle with options of 15kW or 22kW, 4,000 or 6,000 rev/min spindle drive and travels of 1600mm in X, 800mm in Y and 850mm in Z.
There are also options of 24 or 32 tool magazines.
There are two basic designs with the L version configured with linear guideways to provide faster axis movements of 36 m/min across the Richmond 500, 610, 850 and 1020 machines.
The S version, that is more suited to users requiring heavier milling cycles uses a hardened and ground solid boxway arrangement which is available on the Richmond 610, 850, 1020, 1300 and largest in the range the 1600.
Rapid traverse rates are 24m/min on the three smallest machines and 15m/min in X and Y and 12m/min in Z on the two larger varients.
All machines can be specified with either Anilam 6000M or Fanuc OiMC controls with Heidenhain iTNC530 available on request along with a fourth-axis interface.
There is a range of spindle options, again tailorable to customer requirements.
The VMC 500L has a 5.5kW or 7.5kW drive, with BT40 taper while the 610, 850 and 1020 have 11kW, or 15kW BT40 taper units.
The larger 1300, has 11kW or 15kW of power and BT40/50 taper and the 1600 a choice of 15kW or 22kW with BT40/50 taper and maximum speeds of 4,000, 6,000 rev/min, 10,000 rev/min and 12,000 rev/min with a BT40/50 taper.
A Geneva-type carousel tool magazine changer is fitted as standard with 16 or 20 position options and a 10 second exchange while a 24 or 32 tool magazine with twin-arm changer can be specified having a 2.5s change time.
Colchestersales (UK) based in Heckmondwike, West Yorkshire, is to market the latest advanced and high specification range of Richmond vertical machining centres as part of its high technology machining packages involving the Colchester Lathe range of Tornado, Combi and MultiTurn. The machine range is also sold by 600 Centre of Shepshed near Loughborough, UK, where the Midlands-based Colchestersales Technology Centre is also established. Explained Colchester Lathe director Mike Berry: 'Both 600 Centre and Colchestersales (UK) are putting together packages of machines to customers that want to deal with a single supplier that has a known history and good aftersales support, so it was logical to offer the Richmond as a 600 Group product to both operations.' The Richmond range spans a compact 500L with travels of 510mm in X, 410mm in Y and 460mm in Z with 12 or 20 tools, 5.5kW or 7.5kW spindle motor and options of 8,000, 10,000 or 12,000 rev/min to the top of the range VMC 1600S.
This machine weighs a massive 14 tonnes and has a BT50, spindle with options of 15kW or 22kW, 4,000 or 6,000 rev/min spindle drive and travels of 1600mm in X, 800mm in Y and 850mm in Z.
There are also options of 24 or 32 tool magazines.
There are two basic designs with the L version configured with linear guideways to provide faster axis movements of 36 m/min across the Richmond 500, 610, 850 and 1020 machines.
The S version, that is more suited to users requiring heavier milling cycles uses a hardened and ground solid boxway arrangement which is available on the Richmond 610, 850, 1020, 1300 and largest in the range the 1600.
Rapid traverse rates are 24m/min on the three smallest machines and 15m/min in X and Y and 12m/min in Z on the two larger varients.
All machines can be specified with either Anilam 6000M or Fanuc OiMC controls with Heidenhain iTNC530 available on request along with a fourth-axis interface.
There is a range of spindle options, again tailorable to customer requirements.
The VMC 500L has a 5.5kW or 7.5kW drive, with BT40 taper while the 610, 850 and 1020 have 11kW, or 15kW BT40 taper units.
The larger 1300, has 11kW or 15kW of power and BT40/50 taper and the 1600 a choice of 15kW or 22kW with BT40/50 taper and maximum speeds of 4,000, 6,000 rev/min, 10,000 rev/min and 12,000 rev/min with a BT40/50 taper.
A Geneva-type carousel tool magazine changer is fitted as standard with 16 or 20 position options and a 10 second exchange while a 24 or 32 tool magazine with twin-arm changer can be specified having a 2.5s change time.
Monday, May 08, 2006
Extra large lathes have latest CNC systems
With five models and various bed lengths offered, 'extra large' capacity straight bed CNC lathes can be supplied with Siemens 810D conversational Shopturn CNC or Fanuc Oi TC CNC.
With five models and various bed lengths to choose from, XYZ Machine Tools' new 'extra large' capacity straight bed CNC lathes can be supplied with either Siemens 810D conversational Shopturn CNC or Fanuc Oi TC CNC. The model designations - XYZ XL 730, XYZ XL 860, XYZ SL 1100, XYZ XL 1200 and XYZ XL 1500 - denote the mm swing over bed, with the between centres distance varying, depending on model, from 1m to 9m. The maximum cutting length is 300mm less than the between centres distance in every instance.
Spindle motor ratings range from 15kW to 37kW, providing ample power for heavy metal removal and large diameter turning.
All models feature a solid ribbed casting construction, and are fitted with a 160mm spindle bore - except the XYZ XL 730, which has a 130mm spindle bore - and four-jaw chuck as standard.
Similarly, all models feature two speed ranges, with the exception of the XYZ XL 860 and XYZ XL 1100 which have three speed ranges.
Equipment options include fixed and travelling steadies, gap bed and chip conveyor.
With five models and various bed lengths to choose from, XYZ Machine Tools' new 'extra large' capacity straight bed CNC lathes can be supplied with either Siemens 810D conversational Shopturn CNC or Fanuc Oi TC CNC. The model designations - XYZ XL 730, XYZ XL 860, XYZ SL 1100, XYZ XL 1200 and XYZ XL 1500 - denote the mm swing over bed, with the between centres distance varying, depending on model, from 1m to 9m. The maximum cutting length is 300mm less than the between centres distance in every instance.
Spindle motor ratings range from 15kW to 37kW, providing ample power for heavy metal removal and large diameter turning.
All models feature a solid ribbed casting construction, and are fitted with a 160mm spindle bore - except the XYZ XL 730, which has a 130mm spindle bore - and four-jaw chuck as standard.
Similarly, all models feature two speed ranges, with the exception of the XYZ XL 860 and XYZ XL 1100 which have three speed ranges.
Equipment options include fixed and travelling steadies, gap bed and chip conveyor.
3D graphics raise CNC turning confidence
Conversational programming software that is equally useable for single part manual cycles or for full CNC repeat operation will be demonstrated on a CNC turning machine at MACH 2006.
The latest developments by Colchester Lathe to its Manual Guide i conversational programming software, that is equally useable for single part manual cycles or for full CNC repeat operation over a batch of parts direct from memory, will be demonstrated on the top-selling Colchester MultiTurn 2000. The competitively priced machine will be used to show how effortless 'at the machine' programming should be and how solid model 3D graphic simulation gives higher operator confidence before a part is turned. Launched at MACH 2006 on the Colchestersales (UK) stand 5334 the latest version of the mid-range MultiTurn 2000 enables parts up to 400mm diameter by 1250mm long to be swung over the bed.
However, by utilising the gap bed, a swing of 585mm by 165mm is available.
It is the Fanuc OiTc CNC TFT contouring control with the powerful but simple and quick to use Manual Guide i conversational programming that sets this machine apart enabling the operator to manually turn a part using its electronic handwheels with the control screen functioning as a digital readout for tool positioning.
To this, a series of canned cycles can be added to reduce the input required and the operator also has the facility to cut and paste or call-up his own prepared macros to create the toolpath.
Further help is at hand in building a program through an extensive tool library able to store up to 960 tools with the added supporting bonus of virtual tool and solid modelling programs.
There is also a simple teach/repeat memory plus on-screen CAD/CAM using icon-based commands.
For the advanced user, conventional CNC programming can be performed using G-codes.
And, in the same fashion as a normal CNC lathe, programs can be downloaded by DNC or input from a 'flash card' taken from a PC.
The MultiTurn CNC lathe is very competitively priced and provides high levels of functionality that takes full advantage of the 7.5kW spindle drive.
The spindle is carried on a cast iron flat bed with an eight-station 360mm diameter, bi-directional, electrically indexing disc turret capable of holding 20mm by 20mm tool section size and 30mm diameter boring bars.
Quick-change toolposts from Parat, Multifix or Dickson are available on request.
Three-jaw geared scroll or four-jaw independent chucks up to 250mm with a 54mm bore define the capacity of the machine which can also be supplied with travelling or stationary steadies.
The tailstock is No 5 MT and is available with heavy duty or general purpose centres.
The ergonomically positioned travelling Fanuc OiTC control has a large area to view TFT flat colour screen with a 10 GByte hard disk memory and can be moved totally independently of the fully interlocked enclosure which has twin, slide-aside guard doors.
The latest developments by Colchester Lathe to its Manual Guide i conversational programming software, that is equally useable for single part manual cycles or for full CNC repeat operation over a batch of parts direct from memory, will be demonstrated on the top-selling Colchester MultiTurn 2000. The competitively priced machine will be used to show how effortless 'at the machine' programming should be and how solid model 3D graphic simulation gives higher operator confidence before a part is turned. Launched at MACH 2006 on the Colchestersales (UK) stand 5334 the latest version of the mid-range MultiTurn 2000 enables parts up to 400mm diameter by 1250mm long to be swung over the bed.
However, by utilising the gap bed, a swing of 585mm by 165mm is available.
It is the Fanuc OiTc CNC TFT contouring control with the powerful but simple and quick to use Manual Guide i conversational programming that sets this machine apart enabling the operator to manually turn a part using its electronic handwheels with the control screen functioning as a digital readout for tool positioning.
To this, a series of canned cycles can be added to reduce the input required and the operator also has the facility to cut and paste or call-up his own prepared macros to create the toolpath.
Further help is at hand in building a program through an extensive tool library able to store up to 960 tools with the added supporting bonus of virtual tool and solid modelling programs.
There is also a simple teach/repeat memory plus on-screen CAD/CAM using icon-based commands.
For the advanced user, conventional CNC programming can be performed using G-codes.
And, in the same fashion as a normal CNC lathe, programs can be downloaded by DNC or input from a 'flash card' taken from a PC.
The MultiTurn CNC lathe is very competitively priced and provides high levels of functionality that takes full advantage of the 7.5kW spindle drive.
The spindle is carried on a cast iron flat bed with an eight-station 360mm diameter, bi-directional, electrically indexing disc turret capable of holding 20mm by 20mm tool section size and 30mm diameter boring bars.
Quick-change toolposts from Parat, Multifix or Dickson are available on request.
Three-jaw geared scroll or four-jaw independent chucks up to 250mm with a 54mm bore define the capacity of the machine which can also be supplied with travelling or stationary steadies.
The tailstock is No 5 MT and is available with heavy duty or general purpose centres.
The ergonomically positioned travelling Fanuc OiTC control has a large area to view TFT flat colour screen with a 10 GByte hard disk memory and can be moved totally independently of the fully interlocked enclosure which has twin, slide-aside guard doors.
Saturday, May 06, 2006
CNC slant bed lathe halves machining cycle times
Replacing a Japanese lathe, a CNC slant bed lathe's rigidity, acceleration, rapid traverse and quick turret indexing has halved cycle times involving a lot of in-cycle threading.
Maintaining a 25% year on year growth since setting up in 1988, privately owned Northern Hydraulics based in Coalisland, Co Tyrone, Ireland, under managing director Seamus Morris has continually reinvested profits back into the business - which not only helped fund a new 45,000 ft2 modern machine shop but also recently added the latest large capacity Tornado T10 slant bed lathe to the company's plant list of 'blue chip' named machine tools. Since the installation, by Ireland's Colchester distributor Gillen Machine Tools of Balleymena to replace an existing Japanese lathe, influencing factors to halving precision cycle times are put down to the Colchester machine's rigidity, acceleration, rapid traverse and quick turret indexing. Used to complete a lot of in-cycle threading, the machine has reduced the average cutting cycle from four minutes to two on the production of rod ends up to 2000mm long with a bonus of high reliability running 60 uninterrupted hours a week.
The installation has also enabled capacity overflow involving subcontract machining to be brought back in-house, the machine is described as being much quicker and easier to set up and changeover even with batch sizes that vary between 30 and 300 parts.
But what is also important is that the Tornado supports Morris' lean manufacturing methods and has regularly contributed savings equal to two days on batches.
Morris originally had 30 possible machines to choose from in the first listing of contending lathes.
This was whittled down quickly to a short list that was headed by the newly launched Tornado T10 because of its 80mm through the spindle bore, the greater flexibility the Tornado gave for the type of work he needed to produce and what he regards as very competitive pricing for the machine specification available.
The 60 deg slant bed machine has a 26kW drive with a bar capacity of 82.5mm.
Swing over the bed is 600mm and chuck sizes can be either 305mm or 265mm.
However before making the final decision, Morris wanted Philip Gillen, managing director of Gillen Machine Tools, to take him to the Colchester build facility in Heckmondwike, a visit he previously made 15 years ago when buying his first centre lathe.
In fact, when he toured the Tornado assembly line he was extremely impressed with the changes to the factory and the new look Tornado, he maintained, has a 'presence'.
As a result of the visit, he ordered the T10 on a three-week delivery having it shipped to his works on a Friday afternoon.
The machine was installed and commissioned on the Saturday morning by the Gillen team and was in full production by Saturday afternoon! The Tornado was never the cheapest on the comparison spread sheet, he maintains, but the specification and support of the local distributor swung the decision and he insists this has been totally upheld with the performance and immediate acceptance by the multi-skilled workforce.
Northern Hydraulics produces hydraulic rams for the fork lift, excavator, personal height platforms, quarry, crane and recycling industry - all described by Morris as growing sectors.
Produced in imperial and metric sizes to accommodate pressures up to 340 bar, its cylinder bores range from 40mm to 200mm with rod sizes between 20mm and 70mm and cylinder strokes up to 4000mm.
Starting in business as self-employed in 1988, Morris was previously an apprentice at a subcontract company that also repaired hydraulic cylinders, which provided an ideal background.
In his early one-man days he would order material, cut the steel, machine the parts on a Harrison V50 lathe, weld, assemble, test and deliver the cylinder himself to local companies.
'I used to start invoicing late at night,' he reflected but his keenness and skill soon built a loyal customer base that preferred a local supplier to imported products.
His reputation and sharp pricing made it very difficult for competitors, especially in the recessionary market of the time when 19% interest rates hurt and quick delivery was always required because no one wanted to hold any stock.
He quickly grew from a lonely one-man operation to employ four people.
He now employs 45 people with a massive advantage of multiple skills.
Where the business used to be one man, one machine, the company has progressed where one operator now runs several machines giving greater flexibility, better job interest and awareness to everyone of what's happening around the company.
With the Tornado T10 fitted with Fanuc 21i control and Colchester's Manual Guide i conversational programming technology, the on-machine programming by the setters is made very simple with full graphics simulation and verification of the cutting cycle.
As well as machining, Northern Hydraulics assembles and tests cylinders for direct-to-line delivery working a double shift policy over a 4.1/2 day week with a further 1.1/2 days available when required.
Turnover is currently GBP 3.5 million and rising as a result of some GBP 1.5 million spent on the new premises and GBP 500,000 on new equipment in the last two years.
Facing threats of lower pricing from the likes of China, India, Italy and Eastern Europe, Morris changed the core operating criteria of the company bringing it ever closer to customers.
He said: 'Business is not so much about making things anymore, it has become a black art based on service and support.
We have to constantly look for ways to make a customer feel totally comfortable with what we are doing so he is not tempted to seemingly greener pastures.' A prime example is how the company initially provided a design for manufacture input and this progressively led to prototype production.
'We found that customers were delighted to work with us accepting our knowledge of hydraulics, pistons and production, and have readily accepted our input to provide 'cost-down' recommendations they could never even dream of getting from the Far East.' This scenario has expanded further making Northern Hydraulics an integral part of some customers own business operations.
He said: 'We have been integrated into certain customers' supply chain networks and have even linked directly to their sales/order programmes.' Morris warned: 'This requires trust on both sides.' He outlines how certain customers have given passwords enabling them to go direct into the sales and delivery schedules eliminating any contact with purchase management or buyers.
'We pick up the serial number of any cylinder order as it comes in and break it into the relevant component parts for production and assembly.
This enables us to machine the parts to our most cost-effective method, assemble and test.
All that matters to the customer is that we meet the quality, delivery and pricing structure which is already agreed.' Parts produced on the Tornado T10 are mainly tubes and rod ends - a reason for the 80mm spindle bore requirement.
However, piston ends, gland bushes, forgings and castings are also produced.
Such is the capability of the Tornado that tolerances down to 0.02mm are maintained regularly and grinding has been eliminated by using ground bar.
As part of the process development, changeovers have been reduced by working in families of parts, helped by the working relationship with customers and to save resetting chuck jaws for different rod sizes, the setters have developed a range of split brass bushes with a common outside diameter and bored out to suit the different rod sizes.
The bush slides over the rod to protect the ground surface and is held in the chuck while diameters, undercuts, threads etc are machined.
Rods machined on the Tornado can be up to 80mm diameter and 2000mm long.
Maintaining a 25% year on year growth since setting up in 1988, privately owned Northern Hydraulics based in Coalisland, Co Tyrone, Ireland, under managing director Seamus Morris has continually reinvested profits back into the business - which not only helped fund a new 45,000 ft2 modern machine shop but also recently added the latest large capacity Tornado T10 slant bed lathe to the company's plant list of 'blue chip' named machine tools. Since the installation, by Ireland's Colchester distributor Gillen Machine Tools of Balleymena to replace an existing Japanese lathe, influencing factors to halving precision cycle times are put down to the Colchester machine's rigidity, acceleration, rapid traverse and quick turret indexing. Used to complete a lot of in-cycle threading, the machine has reduced the average cutting cycle from four minutes to two on the production of rod ends up to 2000mm long with a bonus of high reliability running 60 uninterrupted hours a week.
The installation has also enabled capacity overflow involving subcontract machining to be brought back in-house, the machine is described as being much quicker and easier to set up and changeover even with batch sizes that vary between 30 and 300 parts.
But what is also important is that the Tornado supports Morris' lean manufacturing methods and has regularly contributed savings equal to two days on batches.
Morris originally had 30 possible machines to choose from in the first listing of contending lathes.
This was whittled down quickly to a short list that was headed by the newly launched Tornado T10 because of its 80mm through the spindle bore, the greater flexibility the Tornado gave for the type of work he needed to produce and what he regards as very competitive pricing for the machine specification available.
The 60 deg slant bed machine has a 26kW drive with a bar capacity of 82.5mm.
Swing over the bed is 600mm and chuck sizes can be either 305mm or 265mm.
However before making the final decision, Morris wanted Philip Gillen, managing director of Gillen Machine Tools, to take him to the Colchester build facility in Heckmondwike, a visit he previously made 15 years ago when buying his first centre lathe.
In fact, when he toured the Tornado assembly line he was extremely impressed with the changes to the factory and the new look Tornado, he maintained, has a 'presence'.
As a result of the visit, he ordered the T10 on a three-week delivery having it shipped to his works on a Friday afternoon.
The machine was installed and commissioned on the Saturday morning by the Gillen team and was in full production by Saturday afternoon! The Tornado was never the cheapest on the comparison spread sheet, he maintains, but the specification and support of the local distributor swung the decision and he insists this has been totally upheld with the performance and immediate acceptance by the multi-skilled workforce.
Northern Hydraulics produces hydraulic rams for the fork lift, excavator, personal height platforms, quarry, crane and recycling industry - all described by Morris as growing sectors.
Produced in imperial and metric sizes to accommodate pressures up to 340 bar, its cylinder bores range from 40mm to 200mm with rod sizes between 20mm and 70mm and cylinder strokes up to 4000mm.
Starting in business as self-employed in 1988, Morris was previously an apprentice at a subcontract company that also repaired hydraulic cylinders, which provided an ideal background.
In his early one-man days he would order material, cut the steel, machine the parts on a Harrison V50 lathe, weld, assemble, test and deliver the cylinder himself to local companies.
'I used to start invoicing late at night,' he reflected but his keenness and skill soon built a loyal customer base that preferred a local supplier to imported products.
His reputation and sharp pricing made it very difficult for competitors, especially in the recessionary market of the time when 19% interest rates hurt and quick delivery was always required because no one wanted to hold any stock.
He quickly grew from a lonely one-man operation to employ four people.
He now employs 45 people with a massive advantage of multiple skills.
Where the business used to be one man, one machine, the company has progressed where one operator now runs several machines giving greater flexibility, better job interest and awareness to everyone of what's happening around the company.
With the Tornado T10 fitted with Fanuc 21i control and Colchester's Manual Guide i conversational programming technology, the on-machine programming by the setters is made very simple with full graphics simulation and verification of the cutting cycle.
As well as machining, Northern Hydraulics assembles and tests cylinders for direct-to-line delivery working a double shift policy over a 4.1/2 day week with a further 1.1/2 days available when required.
Turnover is currently GBP 3.5 million and rising as a result of some GBP 1.5 million spent on the new premises and GBP 500,000 on new equipment in the last two years.
Facing threats of lower pricing from the likes of China, India, Italy and Eastern Europe, Morris changed the core operating criteria of the company bringing it ever closer to customers.
He said: 'Business is not so much about making things anymore, it has become a black art based on service and support.
We have to constantly look for ways to make a customer feel totally comfortable with what we are doing so he is not tempted to seemingly greener pastures.' A prime example is how the company initially provided a design for manufacture input and this progressively led to prototype production.
'We found that customers were delighted to work with us accepting our knowledge of hydraulics, pistons and production, and have readily accepted our input to provide 'cost-down' recommendations they could never even dream of getting from the Far East.' This scenario has expanded further making Northern Hydraulics an integral part of some customers own business operations.
He said: 'We have been integrated into certain customers' supply chain networks and have even linked directly to their sales/order programmes.' Morris warned: 'This requires trust on both sides.' He outlines how certain customers have given passwords enabling them to go direct into the sales and delivery schedules eliminating any contact with purchase management or buyers.
'We pick up the serial number of any cylinder order as it comes in and break it into the relevant component parts for production and assembly.
This enables us to machine the parts to our most cost-effective method, assemble and test.
All that matters to the customer is that we meet the quality, delivery and pricing structure which is already agreed.' Parts produced on the Tornado T10 are mainly tubes and rod ends - a reason for the 80mm spindle bore requirement.
However, piston ends, gland bushes, forgings and castings are also produced.
Such is the capability of the Tornado that tolerances down to 0.02mm are maintained regularly and grinding has been eliminated by using ground bar.
As part of the process development, changeovers have been reduced by working in families of parts, helped by the working relationship with customers and to save resetting chuck jaws for different rod sizes, the setters have developed a range of split brass bushes with a common outside diameter and bored out to suit the different rod sizes.
The bush slides over the rod to protect the ground surface and is held in the chuck while diameters, undercuts, threads etc are machined.
Rods machined on the Tornado can be up to 80mm diameter and 2000mm long.
Advanced machine tools meet many budgets
To be shown at MACH 2006 is an entry-level lathe alongside a recently launched vertical turning centre and other high production models - including multi-axis mill/turn centres with linear drives.
Advanced machine tools meet many budgets To be shown at MACH 2006 is an entry-level lathe alongside a recently launched vertical turning centre and other high production models - including multi-axis mill/turn centres with linear drives. Whilst DMG is the acknowledged UK market leader for 5-axis CNC milling and high-spec turning, this popular perception belies the true extent of the company's expertise. No other company in the world offers its breadth of range that also includes multi axis mill turn, multi axis turn mill machines for both low and high volume production.
Significantly, it also offers the most extensive range of lower cost entry-level turning and milling machines that compete exceptionally well on price without compromising quality.
The main emphasis of DMG's stand at MACH will therefore be on choice.
Whatever the production need DMG has the model to suit both budget and application and there will be a broad range of machines on show to demonstrate that point, several of them never before seen in the UK.
A new entry-level lathe, the NEF 600 Fanuc, will take centre stage alongside the CTV400, a newly launched vertical turning centre and other high production models with linear drives.
A brand new model of vertical machining centre, the DMC635V will also be launched at MACH.
It appears with established high production favourites such as the upgraded DMU50ev linear for 5-axis simultaneous machining and the twin-pallet DMC80FD mill turn machine.
DMG's ability to provide high quality at the lower end of the market is largely thanks to component rationalisation.
Many of the parts used in DMG's higher specification machines also feature in the less advanced models and as both low and high specification machines are made in the same factories, build quality is also uniform.
'DMG can offer a range of machines and control systems to satisfy almost any manufacturing need from the production of a simple turned part to complex structures for aircraft and aero engines,' explained new managing director Tim Hately.
'We have an extremely strong applications team and work with our customers to find the optimum production solution.
We do not just supply and service, we build partnerships for the long term.' Indeed the long term is particularly important to DMG as in many cases it is still supporting machines that were manufactured before their operators were born! Since his appointment last year Tim Hately has placed considerable emphasis on improving after sales and service support.
'DMG develops more products using new technology such as linear drives than any other manufacturer,' Hately concluded.
'And with the exceptionally high standards we are now setting on the service side of our business, we have so much to offer every sector of the manufacturing community and this will be evident at MACH.' * Principal exhibits new at MACH - NEF 600 Fanuc entry-level lathe - the latest NEF universal lathes from DMG provide top performance from a wealth of high-tech features at an unbeatable price.
Successive generations of the NEF brand have brought users excellent value for money and with the new 400 and 600 range, whose prices start at just £31,000, this tradition continues.
No other entry-level lathe in this price bracket can match these new models for their quality, reliability and profit potential.
This price includes Fanuc 210i CNC control with Manual Guide, manual 3-jaw chuck (200mm), eight station turret and tailstock with life centre.
* CTV 400 linear, vertical turning technology at an exceptional price - exceptional performance and flexibility have already earned the CTV linear Series a high reputation in the automotive industry and similar high productivity sectors.
With specific tooling these high-speed vertical turning machines from DMG can also perform auxiliary operations such as milling, drilling and tapping.
This versatility has already enabled manufacturers to reduce unit cost significantly making them much more competitive.
With the addition of the new CTV400 linear to the range DMG has opened up this potential to larger diameters.
With a chuck capacity of up to 400mm this top-of-the-range machine has dual-track loading and unloading that can reduce handling time by up to 40%.
The high performance of the machine is complemented by a wear-free linear drive on the 1620mm X-axis that accelerates at 1G for rapid traverses up to 100m/min.
* DMC 635V - vertical machining centre - the latest generation of DMC V vertical machining centres from DMG has a terrific pedigree.
Its forerunners, the DMC 63 and 103V, were worldwide best sellers and now with a bundle of high-tech features three new models are set to uphold the trend.
With bigger tables and smaller footprints, these new verticals - the DMC 635/835/1035V - have been designed to provide a rapid return on investment.
The machines are characterised by long axis travel, a compact design, excellent performance and highly attractive starting price of GBP 39,950 (UK price) for the DMC635V machine.
They shave 20% off the production time of a typical job providing excellent value for money especially as an alternative for flexible single part machining and small to medium batch production.
The models only differ in the size of their working area; the largest machine in the range allows a work piece up to 1,000kg to be accommodated.
* DMU 50eVolution linear universal machining centre - with 5 NC axes, the newly upgraded DMU 50eV linear is ideal for highly efficient five-sided machining and 5-axis simultaneous contouring.
The NC swivel rotary table pivots the work piece around its centre of gravity and allows undercuts of up to 18 deg.
This new model now has linear drive in the X-axis for more power and precision.
* Other exhibits - Sprint 42 linear CNC auto - this machine allows complete machining of short workpieces with diameters up to 42mm in small to medium batches (65mm for the SPRINT 65).
This machine series replace conventional single spindle cam machines with higher flexibility and greater efficiency.
Integrated spindle drives and linear tool mounts allow simultaneous machining with several tools in up to 10 axes.
DMC 80FD mill turn 5-axis machine The NC-rotary table with direct-drive technology, a torque of 1,600Nm, a holding torque of 5,000Nm and speeds of up to 500 rev/min permit a wide range of milling- and turning applications for large work pieces weighing up to 800kg.
Advanced machine tools meet many budgets To be shown at MACH 2006 is an entry-level lathe alongside a recently launched vertical turning centre and other high production models - including multi-axis mill/turn centres with linear drives. Whilst DMG is the acknowledged UK market leader for 5-axis CNC milling and high-spec turning, this popular perception belies the true extent of the company's expertise. No other company in the world offers its breadth of range that also includes multi axis mill turn, multi axis turn mill machines for both low and high volume production.
Significantly, it also offers the most extensive range of lower cost entry-level turning and milling machines that compete exceptionally well on price without compromising quality.
The main emphasis of DMG's stand at MACH will therefore be on choice.
Whatever the production need DMG has the model to suit both budget and application and there will be a broad range of machines on show to demonstrate that point, several of them never before seen in the UK.
A new entry-level lathe, the NEF 600 Fanuc, will take centre stage alongside the CTV400, a newly launched vertical turning centre and other high production models with linear drives.
A brand new model of vertical machining centre, the DMC635V will also be launched at MACH.
It appears with established high production favourites such as the upgraded DMU50ev linear for 5-axis simultaneous machining and the twin-pallet DMC80FD mill turn machine.
DMG's ability to provide high quality at the lower end of the market is largely thanks to component rationalisation.
Many of the parts used in DMG's higher specification machines also feature in the less advanced models and as both low and high specification machines are made in the same factories, build quality is also uniform.
'DMG can offer a range of machines and control systems to satisfy almost any manufacturing need from the production of a simple turned part to complex structures for aircraft and aero engines,' explained new managing director Tim Hately.
'We have an extremely strong applications team and work with our customers to find the optimum production solution.
We do not just supply and service, we build partnerships for the long term.' Indeed the long term is particularly important to DMG as in many cases it is still supporting machines that were manufactured before their operators were born! Since his appointment last year Tim Hately has placed considerable emphasis on improving after sales and service support.
'DMG develops more products using new technology such as linear drives than any other manufacturer,' Hately concluded.
'And with the exceptionally high standards we are now setting on the service side of our business, we have so much to offer every sector of the manufacturing community and this will be evident at MACH.' * Principal exhibits new at MACH - NEF 600 Fanuc entry-level lathe - the latest NEF universal lathes from DMG provide top performance from a wealth of high-tech features at an unbeatable price.
Successive generations of the NEF brand have brought users excellent value for money and with the new 400 and 600 range, whose prices start at just £31,000, this tradition continues.
No other entry-level lathe in this price bracket can match these new models for their quality, reliability and profit potential.
This price includes Fanuc 210i CNC control with Manual Guide, manual 3-jaw chuck (200mm), eight station turret and tailstock with life centre.
* CTV 400 linear, vertical turning technology at an exceptional price - exceptional performance and flexibility have already earned the CTV linear Series a high reputation in the automotive industry and similar high productivity sectors.
With specific tooling these high-speed vertical turning machines from DMG can also perform auxiliary operations such as milling, drilling and tapping.
This versatility has already enabled manufacturers to reduce unit cost significantly making them much more competitive.
With the addition of the new CTV400 linear to the range DMG has opened up this potential to larger diameters.
With a chuck capacity of up to 400mm this top-of-the-range machine has dual-track loading and unloading that can reduce handling time by up to 40%.
The high performance of the machine is complemented by a wear-free linear drive on the 1620mm X-axis that accelerates at 1G for rapid traverses up to 100m/min.
* DMC 635V - vertical machining centre - the latest generation of DMC V vertical machining centres from DMG has a terrific pedigree.
Its forerunners, the DMC 63 and 103V, were worldwide best sellers and now with a bundle of high-tech features three new models are set to uphold the trend.
With bigger tables and smaller footprints, these new verticals - the DMC 635/835/1035V - have been designed to provide a rapid return on investment.
The machines are characterised by long axis travel, a compact design, excellent performance and highly attractive starting price of GBP 39,950 (UK price) for the DMC635V machine.
They shave 20% off the production time of a typical job providing excellent value for money especially as an alternative for flexible single part machining and small to medium batch production.
The models only differ in the size of their working area; the largest machine in the range allows a work piece up to 1,000kg to be accommodated.
* DMU 50eVolution linear universal machining centre - with 5 NC axes, the newly upgraded DMU 50eV linear is ideal for highly efficient five-sided machining and 5-axis simultaneous contouring.
The NC swivel rotary table pivots the work piece around its centre of gravity and allows undercuts of up to 18 deg.
This new model now has linear drive in the X-axis for more power and precision.
* Other exhibits - Sprint 42 linear CNC auto - this machine allows complete machining of short workpieces with diameters up to 42mm in small to medium batches (65mm for the SPRINT 65).
This machine series replace conventional single spindle cam machines with higher flexibility and greater efficiency.
Integrated spindle drives and linear tool mounts allow simultaneous machining with several tools in up to 10 axes.
DMC 80FD mill turn 5-axis machine The NC-rotary table with direct-drive technology, a torque of 1,600Nm, a holding torque of 5,000Nm and speeds of up to 500 rev/min permit a wide range of milling- and turning applications for large work pieces weighing up to 800kg.
Tuesday, May 02, 2006
Toggle clamps can be released quickly
Leaders in standard parts and workholding equipment, Wixroyd International are well known for their comprehensive, unrivalled range of quality Toggle Clamps.
Leaders in standard parts and workholding equipment, Wixroyd International are well known for their comprehensive, unrivalled range of quality Toggle Clamps. Used in a wide range of industries such as automobile or furniture production, they are particularly useful where quick release clamping or heavy-duty fastening is required. The minimum of effort gives maximum clamping force.
When opened the clamps clear the workpiece allowing easy handling and positioning of parts, when in a clamped position they remain locked.
A small sample of Wixroyd's range includes, Vertical Acting Toggle Clamps, Horizontal Acting Toggle Clamps, Adjustable Height Toggle Clamps, Toggle Clamps with Safety Handles, Push-Pull Toggle Clamps, Latch Type Toggle Clamps and many more.
All have oil resistant, ergonomic handles, rust-free hardened steel bushes to ensure durability and all parts are galvanised.
Wixroyd Toggle Clamps are available in a wide range of sizes and different finishes, including stainless steel.
Leaders in standard parts and workholding equipment, Wixroyd International are well known for their comprehensive, unrivalled range of quality Toggle Clamps. Used in a wide range of industries such as automobile or furniture production, they are particularly useful where quick release clamping or heavy-duty fastening is required. The minimum of effort gives maximum clamping force.
When opened the clamps clear the workpiece allowing easy handling and positioning of parts, when in a clamped position they remain locked.
A small sample of Wixroyd's range includes, Vertical Acting Toggle Clamps, Horizontal Acting Toggle Clamps, Adjustable Height Toggle Clamps, Toggle Clamps with Safety Handles, Push-Pull Toggle Clamps, Latch Type Toggle Clamps and many more.
All have oil resistant, ergonomic handles, rust-free hardened steel bushes to ensure durability and all parts are galvanised.
Wixroyd Toggle Clamps are available in a wide range of sizes and different finishes, including stainless steel.
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