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.

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