A means to an end

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has supplied a large-capacity vertical turning lathe to Unilathe Ltd, a precision subcontract specialist based in Stoke-on-Trent. The machine, a Fanuc controlled Doosan VT1100, has been positioned adjacent to another Doosan VT1100 machine to create a flexible, high-productivity vertical turning cell.

Components are typically machined in small batches, and are made from hard and difficult-to-machine materials that include titanium, Inconel and Jethete (a corrosion-resistant, hardened and tempered steel). A primary objective behind the new VT1100 investment was Unilathe’s desire, and determination, to secure new aerospace business.
Explains Andrew Sims, Unilathe’s managing director: “Our efforts have been [and are] focused on repositioning Unilathe in the sector. We want to move away from being perceived as a company that only offers first and second-stage machining of castings and forgings, to one that can machine and deliver high integrity components from start to finish to aerospace customers – similar to what we provide for customers in other sectors and industries.”
A strategic audit undertaken by the company examined its internal machining capabilities and revealed that its future aerospace ambitions would be well served by strengthening its vertical turning capacity and, in particular, by acquiring an additional vertical lathe adept at undertaking roughing, semi-finishing and finishing operations on aerospace components like rings, seals and rotor shafts.
Says Sims: “We are an advocate of Doosan machine tools; they perform well, are reliable and represent good value. The fact that they are backed by Mills CNC’s applications and aftersales service and support, makes them even more of an attractive proposition.”
For further information www.millscnc.co.uk

NSK ball-screw wins award

The ‘Encouragement Prize’ at the Advanced Monozukuri Parts Awards 2019 was awarded to NSK for its DIN-standard ball-screw.

The award committee recognised the ball screw’s speed and quietness, as well as its potential to enhance accuracy and efficiency in machine-tool applications. NSK’s DIN-standard ball-screw has the capability to provide feed rates up to 100 m/min, the highest for a deflector-type ball screw, says the company. This speed leads to faster machine tools and, subsequently, reduced cycle times in machining operations, saving money for end users. Another factor favoured by the judges was decreased noise levels, at just 4 dB(A).
For further information www.nskeurope.com

New Index CNC from Kingsbury

Index has released a newly developed version of the MS32 six-spindle automatic, with UK availability via sole sales and service agent, Kingsbury. Designed for the series production of precision turned parts from bar up to 32 mm diameter, the machine is quick to set, lowering the economical batch size, and has flexibility in the way it can be configured, extending its range of application.

Notably, the main spindles have a higher maximum speed, up from 7000 to 8000 rpm, and over 50% more power at 19 kW. The multi-spindle machine can be equipped with six pairs of V-shaped cross slides and X, Y, Z axes at each spindle position, with the option of a simpler single-axis NC grooving or drilling/boring slide to serve any of the six spindles. The ability to select speeds and feeds independently at each spindle results in optimal chipping, maximum surface quality, extended tool life and short production times, even when processing exotic materials, says the company.
All cross slides now have a W serration that matches a similar feature ground into the tool holder, whether for a live or static cutter, facilitating its alignment to micron accuracy and speeding set-up. The operator can pre-set the holder externally, then place it on the slide and fix it in position using a quick clamping device from Index. Only a quick turn with the wrench renders the holder ready to use.
Another improvement relates to simultaneous rear end-working capability, as either one or two swivelling, C-axis synchro-spindles now position themselves in two NC axes on a pair of slide-ways, rather than one, and may be equipped with up to six tools, half of which may be driven.
For further information www.kingsburyuk.com

Perfect bore invests £1 million

Having just celebrated its 30th anniversary, Perfect Bore Manufacturing Ltd has invested £1 million in its deep-hole boring services.

The acquisition of a Tibo machine will allow the company to offer shorter lead times in its increasingly busy Large Deep Hole Boring division, which specialises in producing bores from 25 to 165 mm diameter, and up to 2500 mm in length.
To support Perfect Bore’s ‘one-stop solution’, the investment includes a dedicated honing machine that will enable capacity to be released on CNC and vertical honing machines. In addition, the company has extended its premises to enable it to store additional material on-site. Perfect Bore also reveals that its Grinding division is thriving. In fact, this division has doubled capacity and has been attracting a lot of interest, especially since the company’s involvement in a NATEP project to grind a hard-chrome replacement coating.
For further information www.pbm-ltd.com

Digital ecosystem drives lights-out production

A sheet-metal specialist is providing the perfect example of how a small company can build a successful digital ecosystem, bringing its factory in line with the Industry 4.0 philosophy of smart production. Laser subcontractor AFDL operates with between five and eight employees at any one time, and has installed the WorkPlan MES job management solution, which connects seamlessly with its Radan sheet-metal CADCAM system. Both products are from the Hexagon portfolio, geared towards supporting data-driven smart factories.

Installing the WorkPlan job management and quotation with Radquote module has allowed AFDL (Atelier Forezien de Découpage Laser) to become completely autonomous, from quotation through to invoicing, by providing a full overview of orders received, outstanding and delivered, and of the company’s turnover.
Site Manager Stéphane Noailly says: “Previously, we didn’t have production management software, and invoicing was managed by our parent group, Decofor, involving double entry of all our delivery notes.
“We needed to invest in this type of software because of strong growth, and more employees,” says Noailly. “It was becoming too complicated to manage the company’s activities with Excel files. We opted for WorkPlan as it comes from the same stable as Radan, which we’ve used as our sheet-metal production software for over 10 years.”
Focusing on both thick and thin laser cutting, from 0.2 to 25 mm, across a range of steels, stainless steel and aluminium, AFDL has also developed its activities in bending and welding, producing stainless steel tables for the furniture industry, and working for pharmacies and the public sector.

The company has grown recently, and now produces up to 50 orders a day, comprising individual unit parts, through to large series. Prior to installing WorkPlan, Noailly managed everything from order entry to manufacturing, but since the installation and deployment of the software he has been able to free up time to develop the company’s activity.
Combining the WorkPlan and Radquote interface with the automated system for time analysis, production cost estimation, and quotation generation for sheet-metal parts and assemblies, means AFDL has become more responsive, accurate and fair in terms of price, compared to its competitors, says Noailly, which has allowed the company to successfully manage an increase in demand.
AFDAL was created at the end of 2013 with Decofor being its only customer, yet today half of its customers are external.

“I use WorkPlan to generate precise quotations in connection with Radquote, and either duplicate or modify them for similar new orders; quickly transform them into orders; view all orders at any time; or give autonomy to the workshop to generate delivery notes by simply entering the order number, which also avoids missing invoices.
“Recurring orders from Decofor are now managed with just a few clicks,” he continues. “The file is sent in CSV format, and WorkPlan transforms it into a command – no more re-entries or errors. It’s a real time saver, as production can commence immediately.”

AFDL inherited a CNC machine tool which had originally been purchased at auction by Decofor with Radan already installed, and Noailly decided he wanted to continue using the software. Production is now carried out 24 hours a day, seven days a week, with Radan currently powering two Trumatic 3050 laser-cutting machines and an Amada HFT press brake. There are plans to replace one of the laser machines with a Trumatic 3030 automated fibre laser profiling centre, which will enable the company to move into copper and brass cutting for the electrical sector.
According to Noailly, Radan makes the production process as simple and efficient as possible.
“Customers provide us with files in a variety of formats, including: a DXF 2D plan, which we can use immediately; a 3D STEP file which we open in Radan 3D to unfold before working on it in 2D; PDF files which we have to completely redesign; or directly with parts to reproduce them identically. As soon as the file is validated it’s imported into Radan 2D or 3D to be nested and put into production.
“The drawing features built into our Radan 2D module mean we can efficiently design a 2D part,” explains Noailly. “The software also gives us a quick and simple method to repair or simplify geometries from other systems.”
With around 20 regular products to redesign, or files to use, production is divided 50/50 – firstly, a series of parts, comprising more than 50 pieces; and secondly, individual units.
“Thanks to Radan we can produce up to 30 pieces on the same day that the order is placed, which means we can readily adapt to our customers’ urgent demands when they require something immediately,” says Noailly.
“We are only a small company, but the integrated solution of WorkPlan and Radan has brought our factory in line with the Industry 4.0 philosophy of smart production adopted by companies many times our size.”
For further information www.workplan.com www.radan.com