Posts Tagged ‘CNC Lathes’

Vertical CNC Machining for Tough Applications

Rugged vertical machining centre with an 18kW high-torque spindle and through-tool coolant delivery enables a UK subcontractor to efficiently cut SS and Duplex, as well as other tough alloys

The purchase of a new Hurco VMX64 vertical machining centre (VMC) has enabled Pharma Tooling to more than double its maximum component size capacity. The VMC has a rotary turntable and high-pressure coolant delivery through its BT40 spindle. Said owner and managing director, of Pharma Tooling, Phil Vines: ‘My plan is to grow the business and to do that, we have to be able to take on anything that comes through the door, 24 hours a day’.machine bigger components within the Hurco’s working envelope of over 1600 x 850 x 750mm, and we also have the flexibility to produce smaller parts by setting up two or even three together on the table, using the 4th axis if required.’ Vines said that the 18 kW high-torque spindle and availability of through-tool coolant meant that Pharma Tooling can efficiently cut stainless steels (SS) including Duplex, as well as other tough alloys.

Most of the work put on the VMX64 so far has been either prototypes or small batches of one- and two-off.

Some dimensional tolerances, especially for medical and aerospace applications, are tight at +/-0.05mm, a level of accuracy that Renishaw component and tool probing helps to maintain.

All jobs for the Hurco are programmed on the shop floor.

The ease and speed with which this is carried out using the proprietary Ultimax twin-screen control system was one of the principal reasons for Vines selecting this machine tool manufacturer.

With small batch work, fast turnaround is of the essence to ensure profitability.

A 24h lead time from order to delivery is not unusual, particularly for pharmaceutical components.

Vines was already familiar with the benefits of Hurco machines and their Ultimax CNC system from his work at previous companies.

The VMX64 is the first machining centre that he has acquired since he bought the Cheltenham subcontract firm from administration in 2003.

There are eight existing vertical and horizontal machining centres on site, all 4-axis models, which are programmed off-line, batch size on these smaller machines being typically 50-off.

The capacity list also includes four CNC lathes and a new Robofil 300 wire EDM machine that was installed in 2007 at about the same time as the Hurco.

* About Pharma Tooling – based in Cheltenham, UK, around one third of Pharma Tooling’s business is pharmaceutical-related.

Blister pack tooling is regular work, which involves machining a 1.6m long, aluminium bedway that joins the forming and sealing sections in the production line.

The bedway is now machined in ‘one hit’ on the Hurco VMX64, rather than in two clampings as previously.

Aerospace work accounts for another third of turnover and is currently a particular focus for Pharma Tooling, which was granted AS9001 approval during 2007.

The company is a member of the West of England Aerospace Forum and follows cGMP (current good manufacturing practice) guidelines throughout all stages of design and manufacture.

The SBAC (Society of British Aerospace Companies) has recently trained the subcontractor’s 16 staff in lean manufacturing and capacity planning.

The company is aiming to become a signatory to SC21, which is designed to accelerate the competitiveness of the aerospace and defence industry by raising the performance of its supply chains.

Sheet metal fabrication and engineering company reports that the latest CAD/CAM systems have reduced job times from 4h to 30min and improved accuracy and efficiency

Glenrothes, UK-based Fife Fabrications (FiFab), which produces precision sheet metalwork, electro-mechanical assemblies and engineered components, is using Radan and Edgecam software systems to provide continuous improvement in its manufacturing capability. FiFab’s expertise extends throughout the product development cycle from concept design, prototype, trial and evaluation to manufacture.

The company provides its customers with a ‘concept to component’ solution, for low volume specialist and high volume fabrication.

The Edgecam system is a recent purchase, while Radan software was first installed in 1990 to replace an old DOS-based system.

Radan was determined to be the best solution to meet FiFab’s requirements for an advanced CAD/CAM package with a wealth of functionality that would allow a seamless transition between CAD and machining.

* CAD to NC progams – Radraft solves the problems associated with less than ideal geometry from imported CAD files, with powerful manipulation tools that convert it into fully defined machining programs.

The software examines the line and arc geometry and corrects problems such as gaps in profiles invisible to the naked eye but sufficient to stop a profiling machine.

This functionality is key to FiFab responding to customer requirements quickly and cost effectively, said Radan to manufacturingtalk.com.

The company’s impressive machine set-up includes two Trumpf TC500 CNC punch presses, plus CNC lathes, vertical machining centres and a Trumpf TLC L2530 laser profiling machine.

Supported by the advanced features of Radan’s Radpunch system, FiFab has tremendous flexibility and capability to consistently improve quality and service across the whole operation.

Engineering manager at FiFab.

Dougie Smith, said: ‘Our continuous improvement systems, key performance indicators, dedication to lean manufacturing and total quality management focuses the attention of the entire workforce on the need to maintain the highest possible standards of excellence’.

He explained: ‘Radpunch speeds up the process from start up engineering through to punching and improves our efficiency and accuracy.

We have increased output dramatically typically, a job that used to take us four hours is now completed in just 30 minutes’.

RadbendCNC has proved invaluable in allowing FiFab to import customer models of sheet metal parts and assemblies and unfold them accurately.

Offline programming and simulation improves first off reliability while the collision detection feature greatly reduces expensive errors.

Smith added: ‘With many of our customers involved in high tech industries such as aerospace, telecoms and medical equipment, Radan gives us the flexibility and reliability to provide innovative solutions for a broad range of requirements.

Furthermore, working with expensive materials such as aerospace-grade titanium, our ability to maximise material utilisation and automate nesting allows us to streamline production and keep our costs down – savings we can then pass on to the customer’.

Radan said that Radview enables the drawings to be viewed by the quality and production departments, saving time and improving efficiency throughout the business by allowing feedback from users and increasing overall control.

Continuous investment in world-class equipment has resulted in FiFab’s steady business growth, allowing this progressive company to compete successfully against low cost manufacturers in the Far East.

This forward-looking attitude led to the more recent purchase of Edgecam’s system for NC part programming, based on the positive experience with Radan software, service and support.

This installation was key to FiFab extending its precision machining capability to meet the exacting demands of customers in the hydraulics, telecoms, oil, aerospace and defence markets.

‘Edgecam allows us to make 3D models and tool up our lathes and milling machines,’ said Smith.

‘We chose this package following endorsements from other users, which were verified by demonstrations of its 3D modelling capability.

The process is faster and more accurate and quite simply the best tool to enable the engineering manager to do his job’.

Smith said: ‘We employ a rigorous training programme to ensure our workforce is experienced in every aspect of programming our CNC turning and machining centres.

With the support of advanced software systems such as Edgecam and Radan, we can ensure that our commitments to customers are met every time’.

* About Fife Fabrications – established in 1972, the company is one of the UK’s leading manufacturers of sheet metalwork, electro-mechanical assemblies and precision machined components.

FiFab has invested heavily in state of the art plant and employee development, which give added value to customers working in industry sectors including instrumentation, power generation, defence, telecoms and the security and ATM markets within the UK, Germany and the USA.

* About Radan – Radan is the most powerful sheet metal CAD/CAM software in the world, helping customers increase their material utilisation and reduce inventory and offers a significant return on investment.

Radan is a principal brand of the Planit Group recently ranked by CIMdata as the worl’’s fastest growing CAM vendor, with most industrial users.

* About Edgecam – Edgecam, a market leading computer aided manufacturing (CAM) system for NC part programming, offers a complete solution for milling, turning and mill/turn programming with unparalleled ease of use and sophisticated toolpath generation.

Edgecam is a principal brand of the Planit group recently ranked by CIMdata as the world’s fastest growing CAM vendor, with most industrial users.

* About Planit – Planit is a global supplier of design and manufacturing software for the engineering, woodworking and stone industries.

The company provides its customers with products and services that enable them to improve the productivity of their machine tools, shorten design and manufacturing time, optimise material usage and deliver high quality goods and services to their customers.

Planit’s solutions are best-in-class within their respective markets and are integral to the success of thousands of companies of every size around the globe.

DEUBLIN AutoSense Unions for CNC Machining Centers

WAUKEGAN, IL-DECEMBER, 2007 – Deublin Company announces a revolutionary new technology for CNC machining centers. Deublin AutoSense(TM) coolant unions employ a patent-pending technology that automatically senses the type of media, whether coolant, air or MQL.

AutoSense unions are engineered for use with the most sophisticated CNC technology, where machines use multiple types of media, at high pressures and speeds up to 60,000 rpm. User benefits include longer tool life, improved surface finish, increased production, improved chip control and extended seal life.

A proprietary seal design senses the media, and in the presence of pressurized coolant, the seals actuate, operating like a conventional mechanical seal, and transfers coolant to the spindle. In the presence of pressurized air or MQL, the seals operate with a microscopic gap. A mode of operation called "controlled leakage", that prevents contact between seals. In the absence of any pressurized media, the seals "pop-off", allowing indefinite dry run.

In addition to automatic sensing, the coolant union design features optimized flow, which prevents deposit of metal chips and dirt, along with bearing protection and wear resistant silicon carbide seals. The unions are available in rotor or bore-mounted options for a range of typical connection sizes. Custom sizes and configurations are available on request.

A complete catalog of coolant unions for machine tool applications is available with reference information, selection criteria and ordering information.

Deublin is the leading manufacturer of precision rotating unions for water, steam, air, hydraulic, vacuum, coolant and hot oil service. With manufacturing and/or sales

A patented part accumulator system gathers parts automatically allowing the turning centre to run unmanned for extended periods whilst eliminating part damage

Hydrafeed will show its Rota-Rack rotary part accumulator, the Hydrafeed V65 short bar feeder and the new Autofeed full length barfeed system at the UK’s MACH 2008 exhibition. These feeders will appear alongside established products such as the MultiServo 3-80 intelligent bar support unit, the MultiFeed MX1B system and the X-Tract CNC automatic part unloader.

* Part accumoulator for CNC turning centres – the Rota-Rack is a part accumulator for collecting components from CNC lathes.

The patented system gathers parts automatically allowing the turning centre to run unmanned for extended periods whilst eliminating part damage.

Ideal for limited space environments the accumulator comfortably accommodates parts up to 254mm long with diameters up to 76mm.

The compact system has an adjustable height and can be set at the left or right side of the machine to suit the specific needs of the end user.

* Short bar feeder – the Hydrafeed V65 short barfeeder can hold round, hexagonal or shaped bars from 5 to 65mm diameter.

Maximum capacity is ten 65mm diameter bars up to a stroke length of 1.2 or 1.5m.

The V65 is the ideal partner for unmanned production, said Hydrafeed to manufacturingtalk.com.

To maximise production the V65 has horizontal bar bandings that quickly and efficiently deliver the bar to the spindle, whilst an adjustable faceplate, Mitsubishi PLC controller and remote control pendant are included to enhance ease of use.

* Full length bar feeder – alongside the V65 will be the Autofeed full length barfeed.

It has a single guide channel set to deliver a wider range of bar diameters with models holding a 3mm to 32mm or a 5mm to 51mm bar diameter capacity.

With a standard length capacity of 3.2m with 3.7m option, the dimension range of the new Autofeed make it comfortably suited to fixed head lathes of sliding head turning centres.

The bar feeder can feed from left and right hand side of the lathe to give the end user greater flexibility with machine positioning.

With additional features such as automatic bar centre height adjustment, LED light displaying bar remaining length condition and patented bar anti vibration feature, the Autofeed is destined to be a major success at MACH, said Hydrafeed.

* Intelligent bar support unit – also on show at MACH 2008 will be the established MultiServo 3-80 intelligent bar support unit.

Driven by the lathe, the rotating bar support unit turns at the same rev/min as the turning centre to act as a virtual extension of the lathe drawtube bore.

Alongside the MultiServo 3-80 will be the MultiFeed MX1B bar support unit.

Like the MultiServo 3-80, the MX1B has a bar capacity from 3 to 80mm with a reduction linear system to eliminate vibration.

Utilising a standard bar support unit, the MX1B accommodates round bars up to 1650mm in length with special oilon bushings to control and support the bar in the lathe headstock.

These established products will be alongside the X-Tract CNC automatic part unloader that has been developed to safely and efficiently unload parts too long to be caught in standard part catchers.

The X-Tract removes parts through the sub-spindle of twin spindle machines and can accommodate 1.2 or 1.5m bar lengths.

Hydrafeed will be demonstrating its products from the stand by using a mock lathe to demonstrate bar feeding, part removal and part conveying/storage.

* Hydrafeed at MACH 2008, NEC, Birmingham, UK, April 21-25, Hall 5, Stand 5482.

Three CNC turning centres offer reliable ‘one-hit’ machining – including parts too big for sliding head automatics – and a highly user-friendly control system

Macro CNC (Miyano UK) will be showing three Miyano CNC turning centres at the UK’s MACH 2008 exhibition. The machines are claimed to have exceptional capabilities that focus on flexibility and user-friendliness. The machines to be shown in the UK for the first time will be the Miyano BNJ-51SY2, BNE-51SY5 and ABX-64TH3 turning centres.The machines will not only demonstrate user friendliness, said Macro CNC to manufacturingtalk, but also show their ability to conduct one-hit machining and the handling of expensive parts without causing damage.

The BNJ-51SY2 7-axis turning centre is a development of the well established BNJ-42SY turning centre and has a 51mm diameter capacity.

It will suit companies looking to machine complex parts in one set-up in the size range outside that of sliding head lathes.

Macro CNC will also be exhibiting the new BNE-51SY5.

The machine is a development of a customer feedback programme conducted just over 12 months ago.

The 8-axis turning centre has been improved to deliver ease of use, flexibility and unmanned running beyond the scope of competitor machines.

These elements are guaranteed by the following.

* Load monitoring.

* Presetter option.

* Improved lubrication.

* A Fanuc 31i control with all turret positions driven.

* An extended Z-axis stroke on the bottom turret allowing ease of overlapping on each spindle for enhanced productivity and flexibility.

For machining components up to 64mm diameter, Macro CNC will be launching the ABX-64TH3 10-axis, three turret machine at MACH.

Like the smaller diameter range turning centres in the range, the ABX-64TH3 has been equipped to drive down set-up times, increase unmanned running and improve ease of use.

To accommodate these elements demanded by customers the ABX-64TH3 incorporates a manual guide programming system designed to assist the programming of complex components and enhanced control features with in built load monitoring.

The ABX also incorporates a manual retrace function that allows the end user to prove new programming quickly and efficiently, whilst the new double arm pre-setter allows the operator to rapidly set all tooling on the three turrets for main and sub-spindle operations.

* Macro CNC (Miyano UK) at MACH 2008, NEC, Birmingham, UK, April 21-25, Hall 5, Stand 5251.