A fully automatic production cell based around two Heckert five-axis horizontal T45 machining centres from Starrag with integrated robot handling is manufacturing process-intensive planetary gear carriers in half the time taken by conventional methods, while also reducing tool expenditure by around 25% and halving traditional equipment costs.

The capabilities of the T45 machining centres combine effectively with robotised pallet, gripper and tool handling, as well as seamless cell control technology, to ensure Germany-based mechanical engineering and automation specialist Voith increases productivity by producing the carriers in the shortest possible lead times and with high levels of precision and process reliability.

Assuming an annual output of 50,000 parts per year, the system is also enabling productivity per unit area to be increased by up to two and a half times thanks to a reduction in the number of machines being used compared with traditional methods.

From a process perspective, once the component is clamped, an optimally co-ordinated sequence of rough and smooth milling, turning and drilling operations are undertaken by machines with 15,000 rpm, 292 Nm spindles, complemented by fast start-up and deceleration rates, and 60-tool magazines. The extremely short process and throughput times for sequentially machining workpieces that may be of variable design are partly due to the robot‘s ability to automatically set up the required grippers and type-specific pallets in the storage area while the machines are cutting. When the operator approves a new series for production, the robot changes all equipment within eight seconds. This innovative production solution halves the previous process time.

Overall throughput time is also reduced because there is no need to change workpieces between machines – thus, for example eliminating the installation of different clamping devices and re-clamping.

For further information
www.starrag.com

GM CNC has introduced the Victor Vcenter F76 to the UK market for any machine shops seeking a small-footprint three-axis vertical machining centre that is robust, stable, precise and built to last.

Despite its compact footprint, the Victor Vcenter F76 packs a punch with its meehanite casting and A-frame column design. Built upon this foundation is a 15 kW, 8000 rpm BT40 belt-driven spindle that traverses over the 840 x 500 mm table with X, Y and Z-axis travels of 760 by 500 by 510 mm respectively.

The Victor Vcenter F76 can traverse at rapid feed rates of 32 m/min in all three axes. This productivity is complemented by NN-type double roller bearings, 40 mm diameter ball screws and 30/35/45 mm guideways. These technologies help to eliminate backlash and provide bi-directional positional accuracy of 0.010 mm with a repeatability of 0.007 mm.

Affirming this build quality is an overall machine weight of 5260 kg, a FANUC CNC and a barrel-type automatic tool change unit that accommodates up to 24 tools and delivers a tool-change time of 2.4 seconds. As standard, the Victor Vcenter F76 offers fully enclosed splash guarding, screw-type chip remover, air blast, rigid tapping facility, remote MPG, hand tools and toolbox, T nuts for table slots, three-step warning light, and levelling pads.

Some of the options include a spindle upgrade to 10,000 rpm, a 30-tool ATC, an optional 690 mm in the Z axis, rotary tables, coolant and air gun, precision linear scales, oil skimmer, automatic doors, 4th/5th axis interface, auto tool length and part measurement, auto power-off, air conditioning for electrical cabinets, through-tool coolant, and spindle cooling units.

For further information
www.gm-cnc.com

Alpine F1 Team’s recent investment in eight Mikron MILL P 500U five-axis machining centres has had a dramatic and positive impact on the productivity and efficiency of its manufacturing operations. The machines – four with integrated automatic pallet changers and four without – are now operational at the F1 Team’s manufacturing facility in Enstone, Oxfordshire. These eight MILL P 500Us replaced six Mikron HPM 450U five-axis machines that were acquired in 2016. Whilst still performing satisfactorily, the HPM 450U’s days were numbered.

Ian Pearce, Alpine F1 Team’s head of supply chain, says: “The Mikron HPM 450Us are good machines but changing situations and circumstances within our own manufacturing operations dictated that they needed to be replaced as a matter of some urgency.”

The arrival of the new machines has enabled Alpine F1 Team to take advantage of fast rapids (61 m/min) and 1 G acceleration/deceleration rates, as well as gantry-type construction and a trunnion rotary tilting table (with tandem support on its tilt axis).

Front uprights are among the parts now undergoing machining on the MILL P 500Us.
Says Bruce Foster, metallics production manager at Alpine F1 Team: “The uprights are primarily 3+2 machined from solid aluminium, with full simultaneous five-axis machining taking place when and where appropriate and beneficial. Cycle times are about 12 hours per upright, while geometric tolerances across the part are 10 µm or better, along with Ra 0.2 µm surface finish.”
In addition to the front uprights, the MILL P 500U machines produce the cars’ hydraulic manifold from (solid) aerospace-grade aluminium to exacting tolerances. Over 85% of the material is removed during the roughing process, leaving a complex part exhibiting a number of delicate and intricate features.

For further information
www.gfms.com