Vulcan VMC for cost-conscious engineers

The Engineering Technology Group (ETG) says it has risen the bar on cost-effective machining centres with the arrival of the Vulcan VMC650B. Part of the latest Vulcan brand that was launched in 2020, the VMC650B is the smallest model in a line of machines built-upon a box-way design which has been optimised with FEA to deliver high levels of rigidity and performance.

According to ETG, the new three-axis VMC650B is a robust workhorse capable of handling extreme cutting forces and loads, while maintaining smooth motion with increased dampening and cutting force characteristics. This smooth axis movement and vibration dampening are enhanced by an extra-wide saddle and base concept that is complemented by each axis utilising grade C3 precision-ground ballscrews and a pre-tensioned design.

From a specification perspective, the compact VMC650B has a work envelope of 650 x 500 x 500 mm in the X, Y and Z axis, with a spindle nose to table surface distance of 125 to 620 mm. This envelope works over a machine bed of 800 x 470 mm that can accommodate workpieces up to 500 kg. The BT40 spindle taper is provided with cutting tools from a swing-arm type tool facility that can hold up to 24 tools.

Rapid traverse rates of 25 m/min in all three axes guarantee productive machining within a solid build construction that boasts an overall weight of 4800 kg in a compact 2180 x 2040 mm footprint. Adding to this weight and stability is a reinforced rib design in the Z axis that delivers structural strength through the entire casting length.

For further information
www.engtechgroup.com

Quest for productivity leads to Nakamura

Nestled on the outskirts of Dundee, Quest Precision Engineering has been on a trajectory of continuous growth since Gordon Deuchars joined the business three years ago. Operating out of a 20,000 sq ft facility and serving customers in a diverse range of sectors, the subcontract manufacturer has recently bought not one, but two Nakamura-Tome turning centres from Engineering Technology Group’s (ETG) Scottish distribution partner RAM Engineering & Tooling.

Serving customers in the oil and gas, electronics, automotive, and aerospace industries, ISO9001-certified Quest Precision is well versed in machining everything from simple to the most complex of components, from materials as diverse as steel, stainless, plastics, aluminium, Inconel and monel. It is this requirement for the one-hit machining of complex parts from challenging materials that led to the installation of the first Nakamura-Tome turning centre in December 2019, a twin-spindle twin turret WT150II. The impact of the Nakamura-Tome WT150II resulted in a second machine being ordered and installed four months later.

Prior to the installation of the first Nakamura-Tome WT150II, Quest was machining autonomous valves for the oil and gas industry in five operations on four machine tools. Unfortunately, production of the complex 2-inch diameter Inconel 718 valves was time-consuming and not cost-effective enough for Quest to compete with an existing Chinese supplier, leaving the 22 employee company with small-batch work and R&D projects. To win more of the business from the existing overseas supplier, Quest needed to increase productivity and reduce costs; the answer was the Nakamura-Tome WT150II.

Recalling the situation, Quest Precision’s managing director Gordon Deuchars says: “There are 25-30 different valves in the family of parts and, for us to secure more orders, we had to increase throughput and reduce costs. I enquired to a post that Ross Milne from RAM Engineering & Tooling posted on LinkedIn about the WT150II and, within four weeks, we were provided machine specifications, viewed the machine, made our purchasing decision, had a turnkey solution developed for the valves and had the machine installed and running as part of a complete turnkey solution.”

Depending upon the variant, the valves typically have a cycle time from 2 to 4 hours with the majority of valves processed in 3 hours on four machine tools with an additional 25% set-up time across the numerous machines. With valve batches running from prototypes through to production runs of 1000, machining such volumes on the existing machine tools was unfeasible. The installation of the twin-turret twin-spindle Nakamura-Tome WT150II immediately remedied the situation.

Manufacturing the valves in one hit on the WT150II reduced cycle times by 50% to 1.5 hours, while releasing capacity and labour requirements across the shop floor. The impact was so immediate that Quest went out and bought a second WT150II.

“The WT150II made such a difference to our production and set-ups that we ordered a second machine within weeks,” explains Deuchars. “The first machine arrived in December 2019 and the second was installed by March 2020. Instead of using multiple machines and up to five staff on the valves, we now have one operator running the two Nakamuras. With one staff member running the machines by day and another at night, the two WT150II machines have increased our productivity by 500%, making us cost-competitive with China. Furthermore, the machines have reduced our tooling costs considerably due to the set-up and rigidity.”

The result of investing in the two Nakamura machines has been a significant uptick in business from this particular offshore customer.

“We have invested in five machine tools throughout Covid and the Nakamura machines have made a huge impact on our business,” says Deuchars. “Although business levels are not yet at pre-Covid levels, the investment has positioned our business well for the future.

“With regard to our offshore customer, the challenge they had with component supply from China was proximity,” he continues. “If our customer wanted to undertake any R&D work, amend or inspect any parts, proximity was an issue. Now, this customer can jump in a car and visit our facility to discuss projects, look at our production methods and equipment, and investigate opportunities to enhance and develop their product lines with a local supplier.

“Since investing in the Nakamura machines, we have won more business from this customer and the Nakamuras are 95% dedicated to producing the Inconel valves. However, Covid has impacted business and we would expect the required production volumes to incrementally increase into 2022. At this point, we will be making decisions around whether we want to buy more WT150II machines.”

As a vastly experienced engineer and business owner, Deuchars has purchased more than 250 machine tools during his career – so why the Nakamuras?

“I’ve bought machines of most brands and types down the years, but never Nakamuras. However, the reputation of these machines preceded them. In this instance, we knew we needed a twin-turret, twin-spindle machine to achieve efficient one-hit machining. When we looked at the WT150II, the build quality and innovation in the machine was as apparent as the reputation of the brand. What we also needed was an immediate solution without suffering from the lead-time issues of so many machine tool vendors at present. Ross at RAM Engineering fulfilled all of our needs.

“With the valves being a complex family of parts, we needed a turnkey solution and RAM Engineering delivered this, fast,” he states. “We were taken through the specification add-ons we would require to produce the family of valves and this was trialled and proven before delivery, but most impressive of all was having a turnkey solution delivered in less than four weeks. This was only achievable through first-class service and communication, which we certainly received with the support of ETG’s application engineer Steve Howes, who worked in synergy with Quest and RAM. The first machine has now been running around the clock for almost two years and we haven’t had any trouble with it. Both machines have been workhorses that deliver for our business every day.”

Having the insight to invest during the pandemic, Quest Precision has ambitious plans for the future.

Says Deuchars: “We currently employ 22 staff and, within the next two years, we want to take our staff level up to 40 and invest upward of £1.7m in the business. By investing in high-end technology like the Nakamura-Tome WT150II machines, we will grow our market share of the subcontracting industry in Scotland – and we are confident that we can help UK manufacturers to re-shore more work.”

“The WT150II machines have improved and streamlined productivity, reduced costs and enabled us to better allocate our staff,” he concludes. “Additionally, the machines have released almost 15% of capacity from the rest of our facility. We will build upon this over the next couple of years and Nakamura machines will certainly be central to our investment plans.”

For further information
www.engtechgroup.co.uk

Steel processing system for wind towers

A new CNC steel processing machine from Ficep UK is now available to bring greater choice to the UK wind tower and offshore manufacturing industries. With the rapid growth of wind tower manufacturing, Ficep UK has brought to market its Energy CNC machine for steel plate drilling, milling and scribing. The automated Energy machine can handle extremely large and heavy steel plates – up to 30 m in length and 4 m in width.

Suitable for applications including the manufacture of wind towers and pressure vessels, the Ficep Energy is a gantry-style fabrication system, with two separate working areas to optimise plate loading and unloading. Available in different bed lengths, the machine can accommodate longer plates and the table can be sub-divided to create multiple processing zones. For added performance, the Energy starts with two 60 kW spindles that can accept milling tools up to 300 mm in diameter for the milling of plates up to 140 mm thick.

The Energy incorporates a probing system to locate all the critical edges of the part prior to spindle operations. It also includes a tool changer system – mounted on the spindle board – which automates and expedites tool selection and replacement. Notably, it is possible to integrate the system with other Ficep steel processing machines, including the Kronos – a heavy-duty gantry-style system with optional dual drill spindles that increase productivity in steel plate processing.

Says Ficep UK managing director Mark Jones: “The UK wind energy industry is growing rapidly, and so too are the size of the towers. Manufacturers need a reliable and efficient solution that is robust and can handle large expanses of material, which is exactly what our Energy system delivers.”

For further information
www.ficep.co.uk

Machine investment at Meddings Group

The Meddings Group can trace its roots back to the late 1930s when the current chairman’s grandfather started the business. It was in 1941 that the first Meddings pillar drill was developed, a product, although greatly updated, which remains central to the group’s activities. With drill production growing the decision was taken to relocate to the company’s current location in Ivybridge, Devon. This move would not only give room for expansion and the development of its own products, but the acquisition of swimming pool heating manufacturer Thermalec, along with extensive subcontract machining and fabrication capabilities, and an industrial supplies division.

Says managing director Mark Dibbens. “We have re-shored all manufacturing of the Meddings drills and Meddings Thermalec products. Product development will see new drill designs being launched at MACH 2022, as well as expansion of the Meddings Thermalec range.”

To help meet increased machining requirements, Meddings Group has undertaken a major investment programme, spending over £1.4m in the past 12 months on capital equipment and facilities. The latest arrival is an XYZ UMC-5X five-axis machining centre.

Initially the focus of the XYZ UMC-5X will be on Meddings’ own products, with new developments of the company’s drills and Thermalec heaters benefitting from the capability of simultaneous five-axis machining. One example is the new design of pool heater vessel, which at over 100 kg in weight, means that reducing set-ups is a major advantage. Another product machined on the XYZ UMC-5X has seen dramatic reductions in cycle times, with one-hit machining cutting the original cycle time of 15 hours by 50%.

For further information
www.xyzmachinetools.com

MTC sets up in southeast

Future Cube, a new innovation centre designed to support and cultivate London’s innovative manufacturing, logistics and construction businesses, has opened in the heart of the Thames Gateway. Located in Rainham, Future Cube will be home to a range of demonstrators and tools that will help businesses to explore and adopt new technologies. The Future Cube facility is the result of a partnership between Havering Council, SEGRO, the London Riverside Business Improvement District (BID), and the Greater London Authority, with the MTC selected as the lead delivery partner on site.

For further information
www.the-mtc.org