Smaller F-series HMC released by Heller

Following the launch by Heller of the F 6000 travelling-column five-axis horizontal machining
centre (HMC) at the EMO trade show in Hanover last September, the German manufacturer
is introducing another new model. The F 5000, with its smaller working volume of 800 x 850
x 1100 mm, has 1000 x 1000 x 1400 mm axis travels and comes with many different types of
in-house developed, integrated motor spindles.
A speed cutting unit in combination with the HSK-A 100 tool shank (HSK-A 63 optional)

reaches speeds of 15,000 rpm. As an alternative, a dynamic cutting unit is suitable for
universal use at up to 400 Nm and 12,000 rpm. For heavy-duty machining, a power cutting
unit with a gear spindle and 1146 Nm of torque output is available.
The redesigned spindle head is of compact design and high rigidity thanks to the robust 45°,
backlash-free kinematics and short distance between the bearing and tool shank. Swivel
range is 350° for flexible five-sided machining. Customers can specify either a chain-type
magazine for up to 150 cutters or a rack-type magazine with 425 positions for HSK-A 100
tools (489 for HSK-A 63).
Featuring a cast-iron structure, modular design and narrow width at 3.7 m, the machining
centre is configurable to various small-to-medium batch production applications, ranging
from general mechanical engineering through powertrain component machining to
aerospace. The production platform is just as efficient for the manufacture of single parts as
it is for series runs, reports Heller.
As with the F 6000, the F 5000’s capabilities are expandable to include turning at up to 700
rpm, interpolation turning, gear cutting, grinding, power skiving and even friction stir
welding.
For further information www.heller.biz

Big Investment Proves Ideal for KeraJet

KeraJet, an international digital printing machinery manufacturer has recently invested in a
new large-capacity gantry-type mill from Zayer. The machine, an Altea 8000, with its large X-
, Y- and Z-axis travels of 8000mm x 4350 x 1500 mm and 8000 x 3000 mm fixed table, is
producing machine frames, engine bridges and other performance-critical parts that go into
its digital printing machines. Zayer machines are available in the UK exclusively from Mills
CNC.
Says Jose Luis Granell, head of the machining workshop at KeraJet: “Our digital printing
machines are accurate, but such precision is only possible as long as the components that go
into them are machined to tight tolerances and exacting surface finishes. It’s worth bearing
in mind that when it comes to our print-head technology, our machines are working day-in,
day-out for customers achieving accuracies in the micrometre and even nanometre range.”
The Altea 8000 works an eight-hour shift but, if there is call for repeat components and the
process is secure and repeatable, it runs unattended through the night to improve KeraJet’s
productivity significantly. Flexibility is another major benefit of the Zayer machine.
“We can use the machine in pendulum mode machining workpieces up to 4000 mm in
length in both work zones, as well as machining longer parts using the full stroke of the
machine,” explains Granell. “In addition, the Altea 8000 features 30° and 45° heads. When
machining aluminium, for example, we use the 30° head with electro-spindle at 18,000 rpm.
We use the 45° head when machining steel and select the electro-spindle if and when
superior surface finishes are necessary.”
The Altea 8000 also has several onboard software apps that help improve the machine’s
performance and process reliability.
For further information www.millscnc.co.uk

Image Wheels wins £10,000 off any machine from XYZ Machine Tools

Tipton-based Image Wheels has emerged victorious in a prestigious competition hosted by
XYZ Machine Tools at the MACH 2024 exhibition held in Birmingham earlier this year. The
company received a generous £10,000 (plus VAT) discount on the purchase price of any new
CNC machine in the XYZ range. This forward-thinking manufacturing business opted for a
brand new Proturn RLX 555 gap-bed lathe with ProtoTRAK control, aiming to boost capacity
and counteract the current skills shortage.
Founded in 1987, Image Wheels is now a leading UK manufacturer of alloy wheels to
customers worldwide. The family-owned business produces both classic and modern high-
grade alloy wheels to order, supplying over 50 styles in sizes ranging from 10-20” in
diameter, with customisable widths and offsets. Applications include race cars, dragsters,
classic cars, kit cars, trikes and offroad vehicles of diverse types. Keeping pace with the
company’s busy order book requires ongoing investment in the latest manufacturing
technologies. However, there is a notable industry challenge to navigate.
“Finding CNC programmers, setters and operators who can hit the ground running is very
difficult,” reveals Jason Worrall, works director at Image Wheels. “Instead, we’re gradually
upskilling our existing manual machine operators. We can make this task easier by tapping
into the ease-of-use that comes with the ProtoTRAK control.”
Worrall’s visit to MACH 2024 marked his first time at the exhibition, where he visited several
stands to assess potential CNC turning machines.
“I didn’t know about the competition to win a £10,000 discount on any XYZ machine until I
got to their stand,” he says. “I filled out an entry form there and then. XYZ’s area sales
manager John Aspinall, who was familiar to us, phoned me a few days after the show and I
could tell by the excitement in his voice that I had won. It was a great feeling.”
The discount was applied to the popular Proturn RLX 555 gap-bed lathe, chosen for its
sizable turning capacity, impressive versatility and user-friendly ProtoTRAK control. The
machine is already in situ at the company’s Tipton manufacturing facility.
“We only really have one machine for producing large 20” diameter wheels, so with the RLX
555 we’ve effectively doubled our capacity for this type of work,” explains Worrall.
“Although it’s our first XYZ machine, we employed a new operator at the back end of 2023
who has a lot of experience with ProtoTRAK, which means we can get the RLX 555 cutting
metal and earning money straight away. At the same time, we’ll train one of our existing
manual machine operators on the ProtoTRAK. This strategy will help us negate the current
lack of experienced CNC operators.”

Proturn lathes with the RLX 15.6” touchscreen ProtoTRAK control are ideal for one-off and
low-volume production. As the simplest control on the market, machine shops can be
making parts profitably in no time. Even an operator with no previous CNC experience will
be producing complex parts within hours.
The new XYZ Proturn RLX 555 will machine alloy wheels from castings, performing a range of
turning, boring and profiling operations. Image Wheels produces its products from high-
grade cast aluminium, typically in batches of two or four, and sometimes up to 20-off for a
race team. The company, accredited to ISO 9001:2015, has manufactured components for
record-breaking and championship-winning cars all over the world.
Proturn RLX 555 machines offer a swing-over-bed of 560 mm, a spindle bore of 104 mm and
come with a 315 mm three-jaw chuck as standard. Image Wheels opted for the 1 m bed
version, though the Proturn RLX 555 is also available in a 1.75 m model. The machine
supplied to Image Wheels includes numerous advanced options, including the DXF File
Converter.
“Rather than using dimensioned drawings with complex profiles, we can simply output a
DXF file, upload it into the machine, select the contour and away we go,” says Worrall. “It
will accelerate our process and ensure less opportunity for error.”
Quality is paramount at this progressive manufacturing business. Image Wheels
manufactures its products in accordance with British Standards, including BSAU 50 Part 2
Section 5C, BS ISO 4000-2 and BS ISO 16833. The company is a member of the British
Standards Institute, and all wheel designs undergo tests by an independent company using
FEA (finite element analysis).
“Our main differentiator is our products, particularly their quality,” concludes Worrall.
“There are very few alloy wheel manufacturers worldwide who can compete in the same
way. Sure enough, all of us in this industry have business challenges to overcome, with skills
proving one of the most prominent. However, with a bit of fortune that arrived by winning
the XYZ competition at MACH, we’ve found the perfect way forward.”
For further information www.xyzmachinetools.com

Ultrasonic welds on 3D prints

Telsonic UK is collaborating with the Nottingham office of Stratasys, performing a series of interesting 3D-printed polypropylene ultrasonic weld trials. A Stratasys H350 produced parts for the tests. Initial abstract trials were conducted with Telsonic’s 35kHz Handystar Energy handgun system to check the ultrasonic weldability of the material using various techniques. The success of these tests led to further investigation, guided this time by Telsonic UK, with new trial parts having features that reflect real world application shapes and weld preparation features for automotive ultrasonic welded joints.

More information www.bit.ly/3xu8Gso

NMIS bolsters board

The National Manufacturing Institute Scotland (NMIS) is strengthening its non-executive board with the appointment of highly experienced and influential industry leaders Neil Logan and Allan Cook CBE. The duo bring extensive leadership in engineering, manufacturing and digital entrepreneurship to the board. Their expertise will support the leadership team and help NMIS to continue delivering transformative impact across the manufacturing community in Scotland and beyond. The University of Strathclyde operates NMIS, which is part of the High Value Manufacturing (HVM) Catapult.

For further information www.nmis.scot