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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.

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Mid-America Manufacturing offers adjustable workpiece supports that are designed to withstand heavy loads. The compact devices, which are made of Stressproof 1144 steel and feature Acme-style threads, can support as much as 40,000 lbs during machining operations.

The adjustable supports can be used vertically or horizontally and are offered in four sizes ranging in heights from 2″ to 24″. Such adjustability allows faster setups by eliminating the need for shimming. Jam nuts allow them to be locked into the correct height after set up for repeatable part fixturing. The supports are available with flat, spherical, wedge, V-notch or 90-degree, pointed workpiece contacts in addition to 8″ and 12″ clamp bars.

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Dixons Surgical Instruments is using the Mazak Quick Turn Nexus 200-II MSY turning centre to keep ahead of the competition.

Celebrating its 60th anniversary, Dixons Surgical Instruments is proud of its status as a maker of high-quality surgical instruments, and of the craftsmanship that goes along with that business.

Technical director Jay Dixon, grandson of the company’s founder Frank Dixon, suggests that the art of surgical instrument making today revolves around combining modern machining techniques with the traditional crafts of handworking and polishing.

It was back in the early 1990s that Jay’s father, John Dixon, recognised that, with the advent of CNC, many of the parts being produced lent themselves to being CNC machined prior to hand finishing.

This recognition that technology could make life easier was to see the company’s first machining centre installed, quickly followed by a two-axis CNC lathe.

The early foray into CNC answered many of the questions being posed by this new technology while, at the same time, creating new challenges.

‘Our manufacturing is based around a catalogue of specialist instruments that stretches to over 5,000 individual items,’ said Jay Dixon.

‘Our batch sizes tend to be quite small, with 20-off being typical.

‘After a while we recognised that investing in a turning centre was the way to proceed with our investment plan.’ With the decision made, the challenge was to find a suitable machine and, influenced initially by price, the company purchased a twin-spindle, platen-type turning centre.

‘It didn’t take us long to realise that this was not the ideal machine tool, as we were finding that the complex set-ups for this machine and the time involved were far outweighing the initial capital expenditure saving we had made,’ said Dixon.

With the benefit of hindsight and this new-found experience the company renewed its efforts to find the ideal turning centre.

The result was the purchase a Mazak Quick Turn Nexus 200-II MSY.

Featuring twin spindles of 26kW and 11kW respectively, a footprint of 2.8m by 1.86m and a Y-axis movement of 100mm, this proved to be the ideal solution for the compact machine shop.

One of the key boxes that had to be ticked was the machine control.

‘One of our biggest problems has been machine setting time, so the first criteria that we had for the new machine was the control system,’ added Dixon.

‘We needed something that would lend itself to smaller batch sizes and allow us to program, set and get the machine running as quickly as possible.

‘The Mazatrol Matrix control ticked the most boxes.

‘Of particular interest with the Mazak control is the fact that the conversational language made programming much simpler.’ As with all potential customers, Jay Dixon and his colleagues were invited to visit Mazak’s European manufacturing plant in Worcester.

This in turn, played a major part in the final decision-making process.

‘The knowledge that there is a large engineering team ready to provide whatever support that might be needed is a definite buying influence,’ said Dixon.

This support included programming and operator training.

The five-day programming course at Mazak was a revelation to Dixons’ employees, whose previous experience of programming training courses was to be sat in their own canteen with a pen and paper.

While service and support is highly valuable, it is the performance of the machine that ultimately decides how successful the buying decision is.

Jay Dixon has nothing but praise for the performance of the Mazak Quick Turn Nexus 200-II MSY.

‘From a productivity point of view, we are not too interested in shaving seconds off cycle times as we only produce small batch sizes,’ he said.

‘However, the savings we have made, and have still to make, in reducing set-up times will make a significant difference to this business.’ What is key to a manufacturer of surgical instruments, though, is the precision and overall quality of parts being produced, and it is hear that Dixons is seeing major improvements.

Thanks to the build quality of the Mazak machine the company is finding it much easier to machine parts to high standards.

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TandR Precision Engineering has invested GBP1.5m in six CNC machine tools from Yamazaki Mazak including CNC turning centres.

Ray Maddison, managing director of TandR Precision, said: ‘A major contract from one of our longstanding customers drove home the fact that we needed to invest in CNC.

‘Aircraft manufacturers reviewed manufacturing processes in an attempt to reduce costs and improve productivity.

‘The result was components that are an amalgamation of two or three previous parts; to manufacture them efficiently, a five-axis capability became an essential requirement.’ The first Yamazaki Mazak machine TandR bought was a Mazak Variaxis 630-5X II multi-tasking machine tool, closely followed by a Mazak Integrex 300-IV ST multi-tasking machine tool.

Maddison said: ‘In the early days, much of the work we did was in light alloys.

‘But as this started to change to a requirement to machine components in hard materials, such as titanium and Inconel, we needed a machine capable of handling the higher cutting forces and stresses.’ The Integrex’s versatility and its capability to finish machine components in a single set-up has meant the difference on certain tasks between breaking even and making a profit.

The rigidity of the Integrex’s construction allows higher cutting data on difficult-to-machine materials.

The simplicity of its Mazatrol Matrix control system helps speed up the programming of the most complex components.

Four jobs are about to be transferred to the Integrex 300-IV ST, which is expected to reduce their cycle-times by 40 per cent.

A third multi-axis Mazak machine, a Variaxis 500-5X II, has a multi-surface simultaneous five-axis machining capability that is producing a variety of aerospace components.

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RT Quaife Engineering has converted the entire turning section of its manufacturing facility using machines and control systems from Yamazaki Mazak.

For over 40 years, Sevenoaks-based RT Quaife Engineering has been developing specialist transmission systems for motor sport teams.

Investment in machine tool technology is helping to maintain that position.

Quaife’s client base ranges from the enthusiast, through professional teams right up to the OEMs including Ford, General Motors and Daimler Chrysler.

Quaife’s latest OEM success has been the development of the differential that will be used in the latest Ford to take the RS name, the RS Focus.

Quaife has always adopted the latest NC and CNC at the earliest opportunity.

‘Our early decisions to buy on price did not necessarily deliver the value/performance that was required, so some 3-4 years ago, Quaife began the process of converting its entire turning section at its Otford, Sevenoaks manufacturing facility over to Mazak,’ said Mick Quaife, technical director, RT Quaife Engineering.

‘This change was driven by the quality of the machines available from Mazak and a desire to move to a more user-friendly control system.

‘The quality of the Mazak machines was defined with the first five machines that we bought, which came with a good warranty.

‘We only had to call out Mazak’s service department once, and the problem was solved quickly and efficiently,’ added Quaife.

Even though the switch to the Mazatrol Matrix control system was a step change in progress from existing systems, it was found to be extremely easy to use and operators quickly came to terms with the conversational programming.

‘We have had a number of different control systems over the years,’ said Glen Molineux, general manager, RT Quaife Engineering.

‘The Mazatrol system has proved to be very easy to adapt to and we have seen improvements in set-up times as a result.’ Quaife’s latest purchase, which was delivered just three months ago, is a Mazak Quick Turn Nexus 250-II MY, equipped with optional bar feed unit.

As standard the machine features a 4,000rev/min 26kW turning spindle, with a 12-position turret with live tooling capability at each position.

When combined with the 100mm Y-axis, maximum turning diameter is 380mm while the maximum length that can be machined is 580mm.

This latest machine, along with the other five Mazak Quick Turn Nexus machines installed at Quaife, will be used to produce a wide variety of transmission components, including gear blanks and shafts for use in its range of gearboxes and differentials.

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Machine-tool builder Boxford has invested in Integrex and VTC 300C-II machines to help keep the manufacture of machine tools for the education market in Halifax for the foreseeable future.

Boxford makes bench-top CNC lathes, machining centres, routers and manual lathes.
Its machine shop was coming under pressure from the variety of work and the relatively small batch-quantities that it was being asked to produce.

Paul Barraclough, director of Boxford, and Steve Randerson, manufacturing manager, visited the UK manufacturing facility of Yamazaki Mazak in Worcester.

The Boxford employees initially wanted an Integrex multi-tasking machine but, after talking it through with Mazak, bought a VTC 300C-II 18.5kW, 12 000 rev/min vertical machining centre.

The employees decided to have the VTC 300C-II fitted with a partition on its 2000mm table, a feature that has eliminated set-up times at Boxford.

Boxford also invested in Mazak’s CPC software and laser tool probing, to allow precise tool-monitoring and management.

Randerson said: ‘Our criteria were to reduce downtime and increase productivity, especially on the small batches that we are called on to machine.

‘The VTC 300C-II has helped us to achieve these aims, with the ability to set one job while another is being machined, eliminating all of our set-up time.

‘A situation helped by the 48-position tool carousel, which is monitored and controlled, along with the sister tools, by the CPC software.’ The VTC 300C-II has allowed Boxford to retire two ten-year-old vertical machining centres, while at the same time increasing productivity and improving component quality.

Having witnessed these improvements, attention returned to the initial plan to install an Integrex multi-tasking machine tool.

Boxford placed an order for an Integrex 200-IV ST, which features standard twin spindles (22kW and 18.5kW), 18.5kW/12 000 rev/min milling and a 120-position automatic tool change, bar feed and workpiece conveyor.

This machine was delivered in December 2008 and will be used to machine a variety of components and operate lights-out on one-off batches.

Randerson added: ‘The versatility that the bar feed, ATC and workpiece conveyor give us is a tremendous boost to productivity.

‘Our plan is to use a single diameter of bar stock to produce a number of components when we run the machine unmanned.

‘While this will result in some wasted material, the cost savings of being able to run lights-out will far outweigh this expense.’ Any components machined overnight will be straightforward chucking jobs that do not require second-end working.

During the manned day-shift, Boxford will use the Integrex’s second spindle to machine more complex components.

The Integrex will allow seven more machines to be taken out of commission, including every manual machine in the factory and the two Mazak machines providing the bulk of the company’s machining capacity for the short-to-medium term.

However, plans are already being developed for the next stage in the investment programme in the machine shop.

Both Paul Barraclough and Steve Randerson are keen to extend the Mazak presence with an additional horizontal machining centre equipped with either a pallet pool or Mazak’s Palletech system.

Barraclough added: ‘We are already witnessing the productivity boost that we expected from the Mazak machines and we are confident that the investment will be paid back on schedule.

‘In terms of productivity, I would say that after capital investment of well over GBP1m in the last few years, we are producing more here now with 50 employees than we did 25 years ago with 120 employees.’.

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Fuji has announced the availability of its PBS-300TT twin-turret chucker, which performs medium- to high-volume production with short cycle times.

Featuring four-axis simultaneous ID/OD-diameter rough and finish turning, the PBS-300TT reduces process cycle time by about 38 per cent.

The rigid box way construction of the chucker is said to ensure high-quality spindle output.

Equipped with Fuji’s own high-speed three-axis dual-hand gantry robot, the PBS-300TT provides work-piece loading and unloading.

The robot-carrying capacity of the chucker is 6.6lb + 6.6lb, with diameters up to 7in x 4.7in.

The PBS-300TT comes with Fuji’s SP1 Max Robot Controller for faster and smoother simultaneous multi-axis movement to access the front, back, left and right of the traverse axis.

A Fanuc 320i-A CNC control is standard with five-place decimal positioning control (English); four-place metric is also included.

The PBS-300TT operates at a maximum spindle speed of 3,000 revolutions per minute and generates 20HP at the spindle motor.

The turret head features a curvic coupling.

For improved chip flow, the machining position of the PBS-300TT is located directly above a large chip receptacle at the bottom of the machine.

Chips drop straight down from the cutting zone onto the Fuji-built chip conveyor.

The PBS-300TT is suitable for machining flanges, hubs, gear blanks, inner rings and outer rings.

The compact footprint of the PBS-300TT is intended to allow for easy integration into most shop environments.

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Fuji Machine America Corporation has introduced the ANS-300TTS and ANS-320TTS twin-turret automated shaft lathes for high-volume applications with short cycle times.

Featuring four-axis simultaneous operation and Fuji’s own gantry robot, the ANS-300TTS and the ANS-320TTS are claimed to achieve faster cycle times and faster takt for optimal work piece output.

The rigid box construction of these lathes is intended to ensure high-quality spindle output.

Approximately 50 per cent of the process cycle time is reduced by high spindle and cutting thrust.

A honeycomb-constructed column is said to enhance rigidity and reduce machine weight.

Featuring a compact design, floor space requirements are at a minimum.

The footprint of the ANS-300TTS measures 5ft 7in (width) x 7ft (diameter) x 9ft 6in (height), while the footprint of the ANS-320TTS measures 6ft 6in (width) x 7ft (diameter) x 10ft 8in (height).

The included Fuji-designed and -built high-speed two-axis gantry robot enables the ANS-300TTS to carry up to 11lb + 11lb, while the ANS-320TTS can carry up to 22lb + 22lb.

For faster and smoother simultaneous multi-axis movement to access the front, back, left and right of the traverse axis, the ANS-300TTS and the ANS-320TTS are equipped with Fuji’s SP1 Max Robot Controller.

A Fanuc 320i-A CNC control with five-place decimal positioning control (English) and four-place metric are also included.

Both the ANS-300TTS and the ANS-320TTS operate at a maximum spindle speed of 3,500 revolutions per minute and hard-turn with a 20HP spindle motor.

Featuring a curvic coupling, the turret heads on each slide are capable of heavy radial force developed during cuts.

The programmable travelling tailstock features a long stroke of 13.78in.

Suitable for machining pinion shafts, turbo charger shafts, input shafts, output shafts, axle shafts, electric motor shafts and more, the ANS-300TTS and the ANS-320TTS machines turn diameters up to 7.1in and shaft work up to 11.81in long (with the option to upgrade to the ANS-320TTS to machine shaft work up to 23.62in long).

These machines employ built-in robotic automation and in-process auto-gauging for quality control and are engineered with Fuji-custom work holding, all from one source.

This allows Fuji engineers to guarantee takt time, cycle time and CPK with turnkey and run-off solutions that are built for lean manufacturing.

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Available from DMG, the CTX beta 800 linear is offered with the option of +60mm of Y-axis travel to a choice of a 12 or 16-station 40 VDI turret with all positions having a driven tool capability.

The CTX beta 800 linear machine is the mid-range version of the CTX series, which can also be specified with 500mm and 1250mm turning lengths.

The machine has a 34kW water-cooled main spindle capable of delivering up to 380Nm of torque.

The main spindle chuck diameter options are up to 400mm diameter with a swing of 700mm and the counter-spindle chuck is 250mm diameter.

Optional bar capacities are 65mm, 76mm, 93mm and 102mm diameter.

High-precision glass scales are used on both the X-axis and Z-axis to provide positioning within one micron.

DMG’s Ergoline control with a 19in screen, 3D simulation and customisable DMG Softkeys can incorporate either Siemens 840D Solutionline with its Shopturn programming extension, or the Heidenhain Plus IT unit with DINplus and the option for Turnplus interactive programming software.

The fifth generation of CTX beta universal lathes in 500, 800 or 1250 versions give high visibility of the working area through scratch resistant, shatterproof windows produced to an aerospace standard with brushed chrome surfaces.

DMG’s Smartkey provides various levels of machine-user security and its Lightline provides an indication of the machine operational status.

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Faced with global competition, today’s manufacturers need to use technology in a way that allows them to stay competitive or to gain a competitive advantage. These strategies often involve the purchase of new machine tools and other equipment. However, while the latest machine tools can do wonders for productivity, CAD/CAM software packages shouldn’t be overlooked.

Rich Laprade, manufacturing engineer at Walker Magnetics Group, can attest to this fact. As part of an integrated solution to some of its manufacturing problems, the Worcester, Massachusetts-based manufacturer of magnetic workholding equipment purchased CNC Software’s Mastercam X2 CAD/CAM package. In addition to keeping newer machines running at their full potential, the software breathed new life into older equipment by generating more efficient tool paths than the company’s previous CAM package.

Walker Magnetics Group began in 1896 when Oakley S. Walker invented the electromagnetic chuck and founded the O.S. Walker Company. Throughout the next century, the company expanded to provide custom design and manufacturing of a wide range of permanent, electromagnetic and electro-permanent magnet products and systems for industrial applications. Today, Walker delivers products to more than 190 countries worldwide and has manufacturing and research and development capabilities in North America, Europe and Asia.

The company has three primary product families: magnetic workholding, magnetic work lifting and magnetic separation. At its manufacturing facilities, the company does everything from basic machining operations such as milling, turning and drilling to fabrication of sheet metal and the design and manufacture of electrical control devices. Products range from a 3-inch-diameter magnetic driver for a lathe to a 100-inch-diameter magnet used in scrap yards.

As part of an effort to stay abreast of the latest technology, the company purchased a new vertical machining center and a new turning center in Chicago at IMTS 2006. Rather than trying to apply its old CAM program to the newer machines, the company also sought to purchase an up-to-date software package. It eventually settled on Mastercam version X2 and began using the software for milling and turning within a month.

According to Mr. Laprade, even operators with very little programming experience are able to become productive problem solvers with minimal training. “This is because of the software’s inherent user-friendliness,” Mr. Laprade says. “After installing it in November 2006, we had a single person doing all of the programming. Now, we have four people capable of programming.”

Much of the company’s work involves creating deep cavities that hold electromagnetic or energizing coils. “One of the things that we’ve been pleasantly surprised about is how Mastercam can handle that kind of deep-pocketing routine, whether it’s in a turning situation or a vertical milling situation,” Mr. Laprade says.

In another application, the software has enabled operators to minimize the number of tools used in turning operations. They’ve been able to use one tool to perform multiple functions, which was impossible with their previous CAM software. In the past, for example, a necking operation would have required a tool change. Now, the operation can be performed with a single tool because the tool paths that the software uses for the application seamlessly integrate into the program, Mr. Laprade explains.

The company often produces prototype or one-off products, so getting an accurate cost quote is important. The software has proved to be beneficial here, as well. Its “verify” feature provides an envelope for planning and scheduling tools. “If it tells me that the run time is 23 minutes, and I’ve got eight parts to do, we know when and where we can slot that job,” Mr. Laprade says. “It also becomes a planning tool.”

The program has also enabled the company to take advantage of current tooling technology. Its tool library provides users with knowledge about how specific tools and inserts will perform in the cut, allowing them to project production time. In addition, the library allows the company to pick a specific vendor as a solution provider.

“If we can narrow our tool selection to a good, reliable family of tools, as opposed to having many different tools from different vendors, we’re much better off,” Mr. Laprade says. “That’s because now we know the capability of the tooling and can spread that capability across a wider spectrum of machines.”
http://www.mmsonline.com/articles/machining-and-operator-productivity-get-a-boost-from-mastercam.aspx

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