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Mills CNC has introduced the 360 Training Academy in recognition of the need for precision manufacturers to change existing manufacturing methods and business practices.
Jeff Hart, 360 Training Academy manager, said the academy was established and precision manufacturers looking to improve performance should consider CNC programmer training as a strategic and cost-effective way forward.
‘Through investing in high-quality training, manufacturers can get the most from their CNC machine tools by sharpening up the knowledge and skills of CNC machine tool programmers and operators, allowing commercial and bottom line benefits to be realised,’ he added.
Hart said that these benefits include: job set-up completed more quickly and more efficiently; time and resources spent checking and re-checking work is reduced, and the likelihood of having to re-work or scrap jobs is eliminated; machine tool utilisation is improved and production bottlenecks are avoided by being able to exploit the full functionality of machine tools; and higher-value contracts can be won more easily as manufacturers can demonstrate that they have the right people, with the right skills, to deliver on time and on budget.
The 360 Training Academy is part of Mills CNC, a UK machine tool supplier and exclusive distributor of Doosan CNC machine tools in the UK and Ireland.
All CNC programmer training courses have been designed and are delivered by industry experts.
The courses are practical and hands on - the emphasis being on ‘learning by doing’.
Courses take place at Mills CNC’s facility in Leamington, which allows course attendees direct access to the very latest Doosan CNC machine tools and the ability to try out their newly learned skills in real time and in a real manufacturing environment.
Fanuc programmer courses cover everything from two-axis lathes right through to multi-axis turning centres - and milling machines through to mill-turn centres - with specialist and advanced Custom Macro A and Macro B courses also available.
Heidenhain programmer courses cover all aspects of three-, four- and five-axis milling.
All 360 Training Academy CNC programmer courses are supported by course manuals (supplied to course attendees) and, following successful completion, all attendees receive a 360 Training Certificate that details the course they have attended and the skills they have acquired.
‘Although the 360 Training Academy is located at Mills CNC - you don’t have to be a Doosan machine tool user or existing Mills customer to attend these courses,’ said Hart.
‘Since the academy was launched in September 2009, more than 40 per cent of course attendees have been users of other CNC machine tools,’ he added.

Tags: CNC programmer

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IMT has introduced the Procast range of large vertical turning machines at the Milan EMO exhibition.
Models in the range include machines capable of turning 6m-diameter parts that weigh up to 100 tons.
IMT manufactures a complete series of machines - ranging from small machines used for the production of pistons to the large ones used for the production of enormous turbines.
IMT manufactures several ranges of vertical turning lathes - the VBM Procast Line of machines being the largest.
These machines range from a turning capacity of 2.5m up to the largest model that will accept parts up to 6m in diameter.
This machine has a maximum turning height of 4m, with a spindle power rating of 150kW of constant power.
To handle the extremes of power and weight, the machine’s double central column and mobile cross rail are reinforced to ensure maximum rigidity and eliminate torsion bending and vibrations, even when the machine is running at full power.
An optional vertical and/or right-angled 37kW milling head is available to allow for high-capacity milling operations.
Procast lathes may also be equipped with an optional grinding spindle.
Tool changing is performed using single or multiple rotary-disc or horizontal or vertical chain-type tool loaders, and part loading via palletisers is also possible.
The IMT lathes may also be specified with twin vertical slides.

Tags: turning capacity

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Kail has acquired a Matsuura H+630 twin-pallet horizontal machining centre and a Toshiba TMF-10 Vertical Turning Centre from Leader CNC.
With a 26kW table motor and an 11kW spindle motor set upon a fully cast base that gives the TMF-10 an overall weight of over 11 tonnes, the Toshiba met rigidity and power requirements.
Ray Welsh, Kail general manager, said: ‘We had to consider the work envelope of the machine and, above all, the ability to machine as many faces as possible without repeatedly re-setting the castings.
‘The Toshiba has a rotating 1m bed with a 700mm working height that gives us sufficient working space, which drastically reduced setup times.
The setups are further reduced and production cycles improved, with a 24-tool carousel with driven tooling that enables the subcontractor to maintain its tool settings for its 20 to 30 castings that incorporate hundreds of internal component variations.
He added: ‘The bores on the castings vary from 2 to 8in diameter and this demands heavy machining on difficult materials.
‘The Toshiba has BT50 taper tooling that conveniently interchanges with the new Matsuura and, when fitted into an extremely rigid and robust machine, our tool life is drastically improved.
‘The rigidity of the Toshiba TMF-10 has improved surface finishes and production time, while improving tool life by over 100 per cent.
‘We can now take 4-5mm deep cuts with confidence in the rigidity and power of the Toshiba.
Welsh added: ‘This has improved tool life over 100 per cent and cycle times by over 50 per cent.
The machine operators are also said to be finding the Fanuc 18iT control system extremely user friendly.
The graphics system on the control simplify processes, while the canned cycle programme simplifies drilling and tapping on a PCD.
Added to this is the capability to utilise the Toshiba TMF-10 as a turning centre, as well as a machining centre.
Leader CNC installed the machine tool to the specific needs of Kail.
This involved moving the coolant sump to the side of the machine from the front to enable a fork lift to load and unload heavy components into the work envelope.

Tags: machining centres

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Agie Charmilles has launched a range of high-speed three- and five-axis Mikron machining centres equipped with linear motors.
The machines are aimed at precision-component manufacturers looking for increased productivity, improved part accuracy and repeatability, consistently high surface finishes and better control and reliability over the milling process.
They have been designed for the high-speed machining of materials including steel, aluminium, titanium, hardened alloys and exotics.
The three-axis machines - HSM 400 LP and XSM 400 LP - and the five-axis models - HSM 400U LP and XSM 400U LP - were launched at EMO 09.
The 400 LP/400U LP machines feature a range of technologies and design features that aid the performance benefits of linear-motor integration, while negating heat buildup.
They have a rigid and ultra-stable bridge structure, and polymer concrete construction that minimises vibration and reduces thermal drift.
Independent (water) cooling systems on all LP machines’ axes also help to reduce thermal displacement and distortion.
Other features include: direct-drive technology on all axes, providing extra rigidity and reliability, and negating potential pitch or reverse errors.
The simpler and more direct drive chain means less moving parts and less cogging, increasing accuracy and reducing wear and repair costs.
The Steptec Opticool spindle system controls the temperature of the machine’s spindle and spindle bearings, which improves part accuracy and surface finish.
This spindle system, working in conjunction with the LP machines’ Smart Technology software helps reduce spindle warm-up cycle times and ensures high accuracy and reliable machining.
The intelligent tool measurement (ITM) system uses a camera that can measure tools down to 0.002mm and which, by digital recalibration, avoids measurement issues caused by swarf sticking to a tool’s tip/cutting edge.
The ITM system, in conjunction with integrated touch probes, ensures improved accuracy and surface finish, and increased reliability.
Integrated automation on the LP machines increases their flexibility and productivity.
Different size tool changers are available - 20 or 40 position ATCs can be specified with HSK E32 tools and 18/36/68 position ATCs can be specified with HSK E40 tools.
A similar choice exists with LP machines’ workpiece pallet changers (APCs) and means that LP machines can become mini-manufacturing cells in their own right.
The machines also have different swarf/chip management systems, depending on the nature of machining.
The three-axis HSM/XSM 400 LP machines provide users with X, Y and Z travels of 500, 450 and 360mm.
The HSM/XSM 400U LP five-axis machines have 500 x 235 x 360mm X, Y and Z-axis travels, with the machines’ five-axis capability being delivered through a B and C axis.
This enables users to machine multiple surfaces of a component, by virtue of its +110/-110deg of movement in B axis and continuous 360deg of movement in the C axis, in 0.0001 increments.
Rapid rates for HSM LP machines are 60m/min in X, Y and Z axis, and rates in B and C axis are 165 and 250rev/min respectively.
XSM LP machines have feed rates of 100m/min in X, Y and Z axis, with 165 and 250rev/min rates in B and C axis.
HSM and XSM three- and five-axis machines are equipped with a choice of spindles to suit every high-speed machining application.
All LP machines have the Heidenhain iTNC 530 control and feature Agie Charmilles’ Smart Technology software - ITC; ITC 5X and the operator-support system.

Tags: linear motors

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Heller Machine Tools has announced the launch of its advanced F Series five-axis machining centres.
Following the recent introduction of the company’s H Series, the F Series adds four five-axis machining centres, containing SK 40 and HSK 63 spindle tapers, to the Heller range.
The new five-axis machining centre line-up enables potential customers to choose between two completely different machine configurations.
The premium models (FP 2000 and FP 4000) include the provision of rapid pallet changers and are designed to deliver excellent levels of productivity within all high-throughput engineering production environments.
The Heller FT 2000 and FT 4000 five-axis machine-tool variants feature workpiece support tables and are claimed to be suitable for use in production locations.
Both machine types, FP and FT, feature the same axis arrangement as the H series, with a rotary-table B axis, and provide an optimum balance between rigidity and accessibility, according to the company.
The 2000 models offer a work area of 630 x 630 x 830mm, while the two 4000 models provide an increased capacity of 800 x 800 x 1,000mm.
Although the machines use many components from Heller’s modular building-block system, the machine structure and axis configuration of the F Series were specifically designed to meet the demanding requirements of five-axis machining.
At the core of the F Series is the spindle technology.
Customers can choose between three different designs across all models: the PCU 63 power cutting universal spindle for high-performance cutting; the SCU 63 speed cutting unit; and the SCT 63 speed cutting tilt spindle for speed cutting with a fork head.
While the two swivel-head units offer advantages for the complete machining of cubic parts, the fork head is suitable for machining contoured surfaces of any kind.
The F Series has an adaptable tool management system that can be tailored to requirements.
Each machining centre is equipped with a standard tool magazine that can be extended to more than 400 storage places; even oversize or extra-long tools can be accommodated.
The F Series is targeted at a variety of manufacturing sectors, including the automotive industry and its supply chain, machine manufacturers, electronics companies, power generation, subcontractors and the aerospace industry.

Tags: five-axis, machining

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Breton has launched the Ultrix high-speed multipurpose vertical machining centre.
The centre has four or five continuous axes for milling, horizontal/vertical turning and grinding of medium-size parts made of superalloys, steel, aluminium and composite.
The Ultrix is capable of performing complex milling operations with three, four and five interpolated axes, together with vertical and horizontal turning and grinding, on the same piece.
With just one positioning of the piece, work can be performed on superalloys, steel, aluminium and composites.
The direct-drive technology and gantry drive ensure high dynamics and system rigidity, as well as machining quality.
Due to automated systems for pallet change and piece automatic loading/unloading, productivity is increased.

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Czech company Klein and Blazek is using Tornos CNC equipment to make automotive parts for Skoda cars.
The company bought its first Tornos Deco 13a Swiss-type CNC lathe in 2000.
The high production levels and reliability of the Tornos machine, together with good technical support and service, has convinced Klein and Blazek of the value of investing in more machinery made by Tornos.
The revolutionary kinematics of the Deco machines, together with the newly developed PNC Deco control software and the TB Deco programming (supplied as the basis for all machines), fulfilled all the conditions and objectives the company had set itself for the introduction of the new Swiss-type CNC lathes.
Klein and Blazek then bought a second Deco 13a.
This was followed in 2001 with an increased move to automation with an automated Multideco 26/6 six-spindle machine from the Multideco series.
Two years later, in 2003, the company acquired a Multideco 20/6 and its success ensured that another Tornos, a Deco 20a, followed in 2005.
Klein and Blazek pursues the policy of permanently raising the specialist qualification level of its technical staff with employees trained by Tornos in Moutier in programming and operating the Multideco machines.
Part of the training included a detailed, technical examination of the parts being produced.
Tornos also provides product support to Klein and Blazek.
The use of the TB Deco programming software allows Klein and Blazek to quickly calculate the production time for turned parts and with exceptional precision, without requiring testing on the machine.
This helps to achieve an accurate calculation of the price of the new part.
Reacting quickly to a customer enquiry by being able to advise a reliable price helps Klein and Blazek to win new orders.
The software contains programming for all its machine models, an interactive machine library, function definitions, program monitoring, graphic simulation and anti-collision tests.
All machined parts at Klein and Blazek are produced on new, modern production machines that meet all requirements in terms of quality, ergonomics and economics.
For Skoda Auto, Klein and Blazek produces four parts for the 1.2-litre three-cylinder engine - the support plate, counterweight and two spacer washers.
Klein and Blazek is an ISO: TS16949 and ISO: 14001 certified company.
It has a EUR40m (GBP35.7m) turnover and employs 600 staff.

Tags: Deco machines

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Leader CNC has become the sole UK agent for the range of Spanish-built Unamuno turning centres.
This machine-tool range is said to offer a number of technical advantages over more conventional multi-axis CNC lathes.
Since becoming the UK representative at the end of 2009, Leader CNC has already sold its first machine - a Unamuno Optima 36 simultaneous multi-tool turning centre.
The Optima 36 centre has been purchased by Wakefield-based Aqua Mist Fire Protection, a provider of low-pressure water-mist technology.
The new acquisition is being used to produce components for water-mist V sprinklers, low-pressure systems and general water-mist applications.
The new Optima range is available with three variants: the Optima 36, 42 and 50.
With six axes and 22 tool positions including eight positions on the three-axis upper slide and a two-axis gang slide with up to 14 tools, the Optima allows seven tools to be used on the main spindle with another seven on the sub spindle.
As an option, customers can acquire the Optima machine with indexing and power tooling on the gang and upper slides for complex component manufacture and improved productivity.
The Optima 36, 42 and 50 machines have 36mm-, 42mm- and 50mm-diameter capacities respectively, matched by the sub-spindle capacities.
This is supported by good power and rigidity, allowing end users to divide operations between the main and sub spindles.
This enables end users to overlap up to three operations simultaneously using axis super-imposition.
With customers now capable of simultaneous milling and drilling processes, productivity is improved.
This rigidity is claimed to offer good surface finishes, enabling the end user to maintain repeatability and accuracy.
The construction of the Optima range enables it to conduct heavy machining operations as well as intricate and difficult-to-machine components.
The Optima range permits simultaneous overlapped machining on the main spindle with a two-axis gang slide that turns the component front profile while simultaneously using the three-axis upper slide to machine the rear profile to reduce cycle times.
As well as offering simultaneous overlapped main spindle machining, the Optima also enables overlapped machining on the sub spindle.
The three-axis upper slide machines the front of the next part in the main spindle while cutting the previous part with the gang slide.
The Optima is also set up to permit three simultaneously overlapped processes.
The three-axis upper slide and the front tool in the gang slide can machine the next component while using the superimposed feed with the sub spindle and rear gang slide tool; the previous part is machined at the same time.
The optional extra of motorised tool stations enables the end user to increase the scope of the Optima to conduct additional milling operations and, in most instances, to eliminate secondary machining processes.
With simultaneous overlapped milling on the primary spindle using a motorised tool unit, the gang slide can mill the front of the part while using the three-position motorised tool unit in the three-axis upper slide to conduct pocket milling.
This concept reduces the need for secondary operations on machining centres.
The motorised option also allows three motorised operations to overlap on the main and sub spindle.
The Optima can conduct tapping from the three-axis upper slide in the previous part while the front rotary tool in the gang slide drills holes in the face of the next component.
At the same time, the rear rotary tool drills the previous part using the superimposed feed on the sub spindle.
The ability to produce complex components and cycles is simplified by the Mitsibushi 730 multi-axis ISO control or the interactive touch-screen PC control.
Optima machines are complete with a part unloader, a coolant tank and a swarf conveyor.

Tags: CNC

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Otto Engineering markets its products via two divisions: Otto Controls and Otto Communications.
The machine shop is run by John Lang and services the controls division, which manufactures parts for an extensive line of switches and grips used in forklifts, tractors, medical defibrillator paddles, washing machines, F1 steering wheels, B2 bomber flight controls and much more.
The communications division of the Carpentersville, Illinois-based company manufactures and assembles headsets for large corporations and for pilots and military in the field.
When Lang joined Otto Engineering 22 years ago, he knew that as an engineering-focused OEM, Otto had great products but the machine shop was taking too long to produce components and there was too much waste.
The company needed to make parts more efficiently so it could bring prices down on end products and stay competitive.
The ISO:9001, ISO:14001 and AS9100B business added several machines over the next 15 years - including a dozen single-spindle turning centres - and began to make parts in a more modern way.
Employees worked to consolidate and pre-set tools in the turning centres to reduce setup times and streamline production.
When the turning centres were at full capacity, Otto realised it needed more spindles to meet demands.
Instead of simply purchasing more single-spindle turning centres, the company looked at the problem from an engineering perspective and then visited the IMTS show in 2002.
The solution appeared as a multi-spindle turning centre.
The team wondered if it could get the job done using less floor space and less overheads by purchasing one multi-spindle machine instead of several single spindles.
Working with companies such as Nasa, Boeing, Caterpillar, John Deere, Toro and Motorola, as well as the US military, Otto sought to reduce its parts inventory to ‘just-in-time’ levels - from one months worth of parts to one weeks worth of parts - or less.
The plan was to run 400 different part numbers on a multi-spindle with an average lot size of 100 pieces.
But as multi-spindle machines are generally classified as lower flexibility, higher-volume machine tools, the company was determined to find out if a multi-spindle machine could indeed handle its high flexibility, low-volume workload.
A multi-spindle machine turned out to be the solution and the company’s cycle times reduced from one minute to 10 seconds; it made Otto so productive that within just four years it was at capacity again.
It was soon realised that Otto didn’t have the capacity it desired and the machine was not particularly well serviced - leaving the company wide open to lengthy and unacceptable downtime.
‘We were doing a fine job making parts on the multi, but I didn’t like the machine, so I started looking around for another,’ said Lang.
‘When Hydromat highlighted Tornos, I was immediately interested,’ he added.
In January 2008, Otto took delivery of a Tornos Multialpha 8×20.
‘The Tornos has eight spindles instead of six, so I can put more tools in the machine and get more families of parts,’ said Lang.
‘Instead of taking something out and putting something in, it’s already there and ready to go.
‘There were parts that we have on [the Tornos] that for instance we would have liked to put in the other multi, but we couldn’t because there were too many features, grooves, threads and double threads, and as the machine goes around, you run out of stations.
‘With eight spindles you can add a groover and an extra threading operation or another slot and so on,’ he added.
Cycle times have also been reduced using the Tornos.
One particular part that took four minutes on the other multi takes 20 seconds on the Tornos.
And the parts come off 100 per cent complete.
While Lang recognises that the team is not using the multi-spindle the traditional way, the system the company has developed works well.
Otto’s controls division has 15 major product categories with thousands of individual products under each category.
It has 30 full-time engineers constantly working on new products.
This means the Tornos multi-spindle has to be very flexible.
‘Normally when a person buys a multi-spindle, they buy it for making one part and a million of them,’ said Lang.
‘But we will set the Tornos up for 30 pieces.
‘We’ll also set it up for 1,000 pieces or even 15, 50 or 3,500 pieces,’ he added.
No matter what size part the company is making, it always uses 7/8in diameter aluminum to do it.
‘If we’re making a 1/2in diameter case, we make it out of 7/8in diameter,’ explains Lang.
‘The material is there and never changes.
‘After the first program is complete, our setups are scheduled for 15 minutes or less.
‘Most people associate a multi-spindle with a three-day set-up.
‘We’ve reduced our setup times through engineering and pre-set tooling,’ he added.
As an example, one part the company is producing will become a sealed ‘trim’ switch about 1.25in long, with a milled slot in one end and three milled notches in the other.
There is a deep O-ring sealing surface on the inside and a pinhole on the outside.
‘If we set up a part such as this in one of the other machines, it would cost too much and could take hours,’ said Lang.
‘Now, we just push a few buttons and off we go,’ he added.
The company uses pre-set tooling and a single material protocol to save on setup time and the wasted material only costs an average of one dime per part.
‘We actually make more money in the lower volume stuff,’ explains Lang.
‘Someone even orders 15 pieces - there’s not another switch company out there that would set this up for 15 pieces.
‘We do it and make money on it because we can charge more for the switch.
‘I don’t think a lot of people would think to give away the six cents of material difference between the small button parts and the big parts.
‘Because I get money back on the chips, six cents really might be four cents.
‘Plus, if you consider the changeovers - to changeover that bar feeder and all eight collets, pickoff, get it running, knock out the little bugs in it, it’s a day of production,’ he added.
Another idea from Otto is a parts-collection system that was created to help run lights out.
The system has four baskets, each perched over a stainless drawer that rests on a rolling platform.
The whole thing is about 6ft long by 2ft high by 2ft deep and rolls into position on large casters to sit under the parts conveyor catching finished parts as they fall out of the machine.
It separates parts by part program or by hour and helps with quality control - allowing Otto to back track to a particular bin when a problem occurs.
‘Our goal is to have 50-75 parts or work orders through this [Tornos] machine every single month and 500 hours of production,’ said Lang.
‘At the end of the year, that’s 6,000 hours of production.
‘Eventually, we’re going to have four identical bins on the other side of the machine, so on a weekend we can set the Tornos up for eight programs.
‘We can have it run a certain amount of parts in each basket and it will automatically go from job to job without anybody being there.
‘When I get the Tornos up to 300 programs - then I will have the flexibility to go through the families of parts and link them together - by processes and by tools.
‘If we had the work, I could put one person on my two multi-spindle machines on days and one on nights; those two people would out produce the rest of the machines in the shop by 2:1,’ he added.

Tags: machine, multi spindle

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Tornos has reported that its MultiAlpha 8×20 range of multi-spindle automatic turning machines are being used by Stryker to improve the production of medical parts.

Motorex high-performance machining fluids are being used on the machinery.

In its Stryker Spine plant in Switzerland, high-tech products such as implants and poly-axial screws are produced for spinal surgery purposes.

The production of complex components is renowned for needing several separate machining steps, which often involves using different machines that require multiple fixture settings.

Throughput time lengthens and the repeatability of precision levels starts to diminish, making the manufacture of components for the medical technology sector more expensive, since these are very niche products.

Stryker Spine is using the MultiAlpha 8×20 from Tornos for repeatability, precision and speed.

The MultiAlpha has eight motor-spindles capable of operating at different speeds, and this was customised to include a combined tailstock machining facility, two programmable manipulators and in integral workpiece extraction unit.

Tornos said the MultiAlpha 8×20 provides optimum cutting values in every machining situation and has a blocking and positioning fixture on every spindle.

This provides Stryker with a high level of productivity and flexibility.

With scope for implementing a diverse range of tools and a universal programming system, Stryker said it is confident that it has the most efficient machine tool partner for its facility.

Every year, Stryker Spine processes tons of titanium alloy (soft), stainless steel (tough) and chrome-cobalt (extremely tough).

These materials could not be more different from one another.

The same is true of the machining steps involved, with all operations - from turning to milling - always performed at the optimal cutting speed.

This application profile imposes extreme demands on the machine tool and cutting oil.

In particular, the fast dissipation of heat and the cooling action of the cooling system integrated in the oil circuit are key factors in the process of maintaining dimensional integrity.

At Stryker Spine, work is carried out to the nearest micron.

Demonstrating this accuracy achieved by the Tornos MultiAlpha 8X20, only a 1C change in the temperature of the cutting oil would have an impact on the dimensional integrity of the workpiece.

This means that the front doors of the machine should only ever be opened in genuine emergency situations.

In particular, it is on the MultiAlpha 8×20 that the true benefits of the Motorex Ortho NF-X formulation can be seen.

The heat between workpiece and tool tip resulting from the high cutting pressure and the optimum cutting speed is utilised to enhance high-pressure stability.

This is of particular benefit during machining operations.

The homogeneous and stable film of lubricant between tool blade and workpiece acts as a protective cushion.

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