Large workpiece machining solution

High-precision, five-axis machining of components up to 2300 mm long may be carried out productively on the new DMF 200|8 travelling-column machining centre from DMG Mori. Offering travels of 2000 x 800 x 850 mm, the DMF 200|8 offers users in the aerospace and mould-making industries, for example, scope to machine long components up to the maximum table load of 2000 kg. Rapid traverse in the linear axes is 50 m/min as standard, but with an optional linear drive in the X axis, the machine reaches 80 m/min. Holistic cooling throughout the machine delivers long-term accuracy and tight tolerances.

The B-axis milling head with 6000 Nm maximum clamping torque offers a swivel range of ±120° for flexible five-axis machining. A 15,000 rpm speedMASTER spindle is standard, while an extensive choice of other modular spindles is available, including a 200 Nm high-torque variant and a 20,000 rpm high-speed version. All come with a 36-month warranty, regardless of running hours.

DMG Mori’s new machine is equipped with a Siemens control and the latest version of the company’s proprietary APP-based user interface, CELOS. So users are well equipped for digitalised production and automation, for example through the attachment of the manufacturer’s PH Cell automatic pallet changer.

The DMF 200|8 features a novel tool change mechanism, which takes place behind the table for fast, safe, collision-free cutter exchange, so the entire clamping surface is available for use. Compared with the predecessor model, the working volume is over 50% larger, creating new possibilities for machining complex components. The ability to employ 400 mm long tools is said to be a unique selling point in this machine class.

For further information
www.dmgmori.com

DMC and Produmax drive new era

The Digital Manufacturing Centre (DMC) has struck a new partnership with precision engineering expert Produmax. As a result, the DMC’s capabilities will be greatly enhanced, with the two organisations combining resources, talent and engineering expertise to drive the automated and digital future of additive manufacturing.

The agreement will enable the DMC to offer end-to-end component development and production for companies operating at the forefront of the aerospace, motorsport and automotive sectors. From engineering consultancy and design-for-manufacture to final machining and inspection, DMC promises a complete, collaborative and connected manufacturing solution. The partnership will combine the best in additive and subtractive manufacturing, alongside comprehensive engineering support and secure supply chains.

For further information
www.digitalmanufacturingcentre.com

High-speed automated machining

Speedio 30-taper, three- to five-axis machining centres built by Brother are able to produce components in such short cycle times that it is difficult to load raw material and unload finished parts by hand quickly enough. So to maximise production efficiency, the Japanese machine manufacturer introduced a robotic handling system, Feedio, at the EMO machine tool show in 2017.

Now, an automated cell comprising both products is available for demonstration in the showroom of UK sales and service agent, Whitehouse Machine Tools. The cell can show manufacturers the suitability of the configuration for unattended and overnight running in high-volume production environments.

A Speedio M300X3 trunnion-type, five-axis mill-turn centre has been chosen to demonstrate the benefits of the Feedio automatic load/unload system. The machine is able to perform prismatic and rotational metal cutting in one hit within a 300 x 440 x 305 mm working volume.

Notable features include a BIG-Plus face-and-taper contact spindle that accelerates from zero to 16,000 rpm in 0.2 second, a -30 to +120° tilting table axis, high-output turning capability that generates a maximum torque of 102 Nm and rotational speeds up to 1500 rpm from zero in less than 0.3 second, and a Brother control with increased memory for holding multiple programs.

To extract the most from this specification, the machine is linked to a Feedio component storage and robotic handling system developed jointly by Brother and ABB. This plug-and-play automation solution is able to serve either one machine, or alternatively two to enable op 10 and op 20 machining of prismatic parts on six sides. The automation unit is designed specifically for Speedio machines, rather than being a generic solution provided by a third party.

For further information
www.wmtcnc.com

HB Bearings opts for Leadwell

In August 2021, a pair of BT40 vertical machining centres built in Taiwan by Leadwell was supplied by UK and Ireland agent WH-Lead to the Holmfirth factory of HB Bearings, which less than a year previously had increased its turnover by one third through the acquisition of Gamet Bearings.

Low-volume manufacture of both bearing ranges, which include precision radial, taper roller, deep groove ball, cylindrical roller and angular contact, as well as many other types, is now under one roof at the Holmfirth factory, where a purpose-built extension houses some of the production equipment from Gamet Bearings.

The new Leadwell machines, a four-axis V-30iF model with rotary table and a five-axis V-40iT trunnion-type machining centre, strengthen the company’s production capacity. A wide range of materials are involved, including stainless steel, tool steel, plastics, bronze, aluminium and exotic alloys. The bearings are often specials, new designs or obsolete types that may need to be reverse-engineered to keep old manufacturing plant, steel mills, mining equipment, oil rigs or classic cars in operation.

Graham Hirst, managing director of HB Bearings/Gamet Bearings, says: “We have prioritised the purchase of these Taiwanese machines ever since we bought our first one, a machining centre, more than 25 years ago. We sold it when the two new machines arrived, with a view to pre-empting its eventual failure. However, right to the end it still milled dowel holes in 62 HRc steel to within 10 µm.

“We now have five machining centres from Leadwell, including two recent models installed in August 2017, which are just as well-built, accurate and reliable.”

For further information
www.wh-lead.co.uk

Radan delivers higher profit margins for Alpha

Automatic nesting capability in Radan CADCAM software is achieving a sheet-metal subcontractor’s target for its raw material utilisation as part of its ‘smart factory’ vision. Alpha Manufacturing provides a full range of sheet-metal services across a number of sectors, including automotive, agricultural, healthcare, retail and electronics.

The company was established in 1989 specifically to manufacture products for its sister company, Bri-Stor Systems, which had been set up six years previously. Bri-Stor is a specialist in light commercial vehicle conversions, supplying internal racking, roof equipment, on-board power and accessories.

Bri-Stor and Alpha Manufacturing share a 35-acre site at Hixon, Staffordshire. The former’s solutions comprise consultancy and design, through to in-house manufacture, installation and livery application. Customers range from those with just a few vehicles, to hundreds, and include many well-known UK fleets.

Modular products for standard conversions include options designed for particular sectors, while bespoke solutions create kits which are fully customised around the specific needs of the customer’s fleet. For example, the Vantage range is an innovative storage system that maximises the usable space within the van. Unlike most internal racking systems, this features an asymmetric design which allows up to three times more tools or materials to be stored.

Initially Bri-Stor outsourced its sheet-metal fabrication requirements, before the decision was taken to build up its own manufacturing arm with Alpha Manufacturing.

Alpha’s marketing manager Chris Kidney says: “Originally we were dedicated to producing the van kit-out components for Bri-Stor, but fast-forward to today, and we now have a large portfolio of subcontract work, which actually outweighs our Bri-stor production.”

All components for both sides of Alpha’s business go through the dedicated sheet-metal CADCAM software, Radan, from Hexagon Manufacturing Intelligence. Kidney says it is extremely important that the parts are high precision, often needing to be within ±0.2 mm. The process begins with laser cutting and punching on Trumpf, Bystronic and Pullmax CNC machines programmed with Radan tool paths and nests, before moving through the factory for folding, fabrication, welding, powder coating and assembly.

“Our biggest challenge was meeting customer deliveries on time, which Radan overcomes with its speedy programming, and by nesting components for individual van conversion kits on the same nest,” explains Kidney.

The company’s team of three full-time programmers makes full use of Radan’s nesting functionality, analysing the true shape, material and thicknesses of all components in a batch, separating and sorting automatically, to produce manufacturable, high-utilisation nests both from full sheets and offcuts.

Says Kidney: “As there’s no limit to nesting components of different sizes and shapes onto different materials and thicknesses, this delivers substantial material savings and improves machine efficiency.”

When the nests have been finalised and are ready for cutting, two of Alpha’s machines – a Trumpf TruPunch 6000 laser-punch combination machine and a Trumpf S12 punch press – can both feed off a Stopa automated storage system which leads to even greater efficiency and time savings. The entire Stopa system now runs 62 m down the centre of the factory, and contains 230 pallets capable of storing a total of around 600 tonnes of sheet metal. This automated system manages the process of stock storage and movement between machines, with all raw sheet metal stored in the towers from where it can be retrieved at the touch of a button.

Programming manager Mark Clews takes up the story: “At the very start of the process, our design team are given a SolidWorks drawing which they break down into a DXF file. This is then imported into Radan. The programmers open the file, along with the nesting works order, which tells them exactly what requires programming. They put that into their nesting schedule; sorting it into parts of the same thickness and those of different thicknesses. The tool paths are applied at the nesting stage to maintain the quality and integrity of the parts, while optimising the cutting sequence, enabling the machine tool to attain its full potential.”

Kidney adds: “The fact that we can process the parts extremely quickly from initial design to getting them on the shop floor ready for machining, has a significant effect on delivery times to Bri-Stor and subcontract customers, which in turn, improves our profitability.

“We’re currently pushing towards automation, high efficiency and lean manufacturing,” he continues. “The focus of this plan is on utilising high-tech machine automation to realise a ‘smart factory’ vision. Today, close to £4m has been invested to secure Alpha’s position as one of the most technically advanced factories in the industry. The Stopa storage system is a major part of that, and Radan plays a vital role with quick, powerful automatic nesting and good sheet utilisation.
“We have a standard procedure that every sheet we nest must be utilised to a minimum percentage. And we achieve that, thanks to Radan.”

For further information
www.radan.com