Toolmaking and subcontract CNC machining specialist DSM-NE, based in Newton Aycliffe, has increased its stock of Hurco machining centres to seven, including a large three-axis model and an even bigger five-axis machine, the company’s first.
One job in particular has benefited enormously from its arrival. A tool steel (P20) die nest, part of a progression moulding machine, initially took 75 hours to machine in six separate set-ups on a Hurco three-axis machining centre. According to DSM-NE’s technical director, Andrew Wilson, the cycle would have reduced to 50 hours after process optimisation.
However, the same job is completed on the Hurco VMX60SRTi five-axis machine in two operations, taking five hours and eight hours respectively. This is around one-quarter of the best possible time on a three-axis machine and has turned what was originally a loss-making contract into profit.
“We looked first at fitting a two-axis rotary table to a three-axis machine because nobody here had experience of operating a full five-axis machining centre,” says Wilson. “However, we saw the VMX60SRTi demonstrated at a Hurco open house in High Wycombe and were impressed at how easy it was to program.
“We were familiar with the 2D programming capability of Hurco’sWinMax conversational CNC system, but it can also create quite complex 3D/five-axis routines involving two positional axes, which takes only a few days to master,” he adds.
For fully interpolative five-axis cycles, DSM-NE employs two seats of Autodesk’s PowerMill CAM software, which are also used for producing more complex three-axis routines. However, half of all programs at Newton Aycliffe are generated on the shop floor at the HurcoWinMax controls.
The controls allow intuitive, menu-driven data input via a touch screen, with a second screen on the five-axis machine for simultaneously displaying a graphic of the part as it is built up. All controls accept DXF drawing files directly from the subcontractor’s CAD system, lightening the load on the CAM department. WinMax can easily take over programming of mould plates, for example. Wilson points out that with most other control systems, this would not be possible.
Technical manager Steven Guz highlights another benefit of the WinMax control, namely its Ultimotion software algorithm that optimises look-ahead throughout the cycle to speed and smooth the milling process, even around sharp corners.
“Identical programs on our older Hurco machining centres without Ultimotion take half as long again to finish, and the absence of chatter considerably improves the surface finish of machined components,” he says.
Today, DSM-NE’s business is divided into three parts: subcontract CNC machining; manufacture and repair of plastic injection moulds and compression moulds, particularly for the automotive industry; and injection moulding of plastic parts mainly for the automotive, medical and agricultural sectors.
The subcontract milling, turning and wire erosion side of the business has grown steadily since 2011 to account for one-third of turnover. It is largely down to the success of one of the subcontractor’s OEM customers specialising in LED lighting, for which DSM-NE is sole supplier of machined aluminium housings and heat sinks. Other contract machining on site involves producing ancillary parts for moulding machines. Offshore work normally accounts for a reasonable proportion of turnover, although this sector is subdued at present.
The broad base of the firm’s current activities stems from the outflow of toolmaking, mainly to the Far East during the last decade. It is true that significant income was retained by correcting poorly made imported tools, work that sometimes cost half as much as the originals, but it was clear that this could not be relied upon long-term.
Shortly after the company moved into its current premises on the Aycliffe Business Park 20 years ago, the first Hurco vertical machining centre (VMC) was purchased, a VM1, which replaced a manual tool-change milling machine from the same manufacturer. A larger BMC 4020 VMC followed shortly after.
The latter machine ran reliably for 22 years and was eventually replaced by a VM2 during 2008. In the same year, a Hurco TM8 turning machine was installed, the first CNC lathe on site, to streamline the manufacture of parts for compression moulds and to open up general subcontract machining opportunities. Subsequently, in the run-up to purchasing the two big VMX machines, DSM-NE added three Hurco VM20s in as many years to cope with increasing volumes of LED lighting components.
“We continue to buy Hurco machines not only because of the commonality of programming and operation, but also because they are reliable and competitively priced,” says Wilson. “The latest five-axis machine was half the price of a similar model from another supplier we benchmarked.”
Looking to the future, he sees growth opportunities in full five-axis machining. The VMX60SRTi has already taken over three-axis work from other vertical machining centres, which it completes more economically using 3+1 and 3+2-axis cycles in fewer set-ups.
Contracts are being sought that can exploit its simultaneous four- and five-axis machining capabilities, which is enhanced by the B-axis spindle head and rotary C-axis configuration, the latter being flush with the machine table. This arrangement offers a bigger machining envelope than an equivalent trunnion-type, five-axis model, especially for three- and four-axis work, and was the reason that this style of machine was purchased.
For further information
www.hurco.co.uk

With its core business being turning, the milling capability at Batchflow Engineering had taken something of a back seat. However, with the growth in low-volume production and prototype work, especially for the motorsport sector, managing director Steve Packwood recognised the need to bring machining centre capacity up to date.
Founded in 1986 by Packwood’s father David, with just a couple of capstan lathes, Batchflow Engineering has grown into a fully evolved CNC subcontractor by investing profits back into the business. While the focus remained on turning, the company had a small milling/machining centre capability to support existing customers. As demand grew for more milling capacity, particularly second operation work, Batchflow considered using its advanced mill-turn capacity as an option. However, for smaller batch quantities and prototype work this was not always the most efficient use of that capacity, so thoughts moved towards dedicated machining centres.
“We knew we had to replace our existing, ageing, machining centre and a visit to an exhibition introduced us to the XYZ 2-OP,” says Packwood. “As soon as I saw it, I realised that we could make full use of its capacity, while the small footprint would be perfect for us at the time. The decision to buy it was one of the easiest capital investments I’ve ever made, given the machine cost and the efficiency that it would bring to the business.”
The XYZ 2-OP had a number of features that particularly appealed to Batchflow; firstly its size, with a footprint of just 760 x 1220 mm it is compact enough to fit almost anywhere in any machine shop. The eight-position toolchanger adds to the machine’s versatility and the 3 hp, 6000 rpm spindle allows a variety of parts and materials to be machined efficiently, especially when combined with the machine’s rigid construction.
Another key element of the 2-OP was the machine table and its integral Jergens Ball Lock fixture location system.
“The Jergens system is perfect for us as we produce relatively small batches, so set-ups are frequent,” explains Packwood. “With the Ball Lock we can quickly position fixtures, knowing exactly where they are on the table, which reduces set-up time considerably.”
The success of the machine meant that Batchflow’s next investment in milling capacity would also come from XYZ Machine Tools. This time Packwood opted for an XYZ LPM (Lean Production Machine) due in part to the use of the Jergens system on this machine and the ProtoTrak control. The ability to switch jobs easily between the two XYZ machines, thanks to the Jergens Ball Lock system and the ability to transfer programs seamlessly between the two controllers, made perfect sense and once again made set-ups extremely short.
“The fact that the LPM machine has the same control and fixturing system as the 2-OP made the decision more straightforward,” says Packwood. “Among the work we do for the motorsport sector there is a significant element of small batch and prototype work, but lead times are always very short, so anything that helps to reduce downtime is a major benefit. It is ideal for a typical subcontractor like ourselves and allows us to provide a rapid response to our customers.”
The XYZ LPM machine expands on the machining capability of the 2-OP with a 15 hp, 8000 rpm BT40 spindle, and a 900 x 500 mm table featuring axis travels of 785 x 470 x 530 mm. An integral toolchanger has capacity for 16 tools, which can be pre-set using the supplied tool presetting system. Furthermore, the ProtoTrak PMX control allows users to carry out background editing of programs while the machine is running, providing further opportunities to reduce set-up time for the next job.
“When we ordered the 2-OP we’d never bought from XYZ, but it provided a low-risk entry into working with a new machine supplier,” says Packwood. “We shouldn’t have had any concerns as both the 2-OP and the LPM have run perfectly. Training on the ProtoTrak control was minimal, as that was all that was required. Overall it has been a very positive experience moving from our previous machines to the XYZs. Add to that the benefit that the interchangeability between the 2-OP and the LPM bring, such as knowing exactly where fixtures are located, reduced set-ups and the versatility of knowing we can do most jobs on either machine, and we have a big advantage with the type of work we undertake.”
For further information
www.xyzmachinetools.com