Five-axis HMC is built in the UK

Heller has introduced a new model to its five-axis, horizontal-spindle machining centre range. The HF 3500 is one of the models being built in the new manufacturing flow line at its Redditch factory, along with the larger HF 5500 and numerous sizes of four-axis machine for global markets.

Intended for five-sided or simultaneous five-axis machining of medium to large batches of complex prismatic parts, the HF 3500 can process small workpieces to heavier components up to the 550 kg maximum table load. An optional ‘Speed Package’ enables 10 m/s2 acceleration and rapids of 90 m/min to be achieved, reducing chip-to-chip time by approximately 10% compared with the standard machine.
Working volume is defined by X, Y and Z travels of 710, 750 and 710 mm. Feedback of axis position to the control is via linear scales for maximum precision. The machine can be equipped with a lift-and-rotate pallet changer for series five-sided production, while pallet automation solutions are also available.
With regard to configuration, the fourth and fifth axes are provided by a rotary table on a +30 to -120° swivelling trunnion, both with direct drive, which moves towards the spindle rather than vice versa. According to Heller Machine Tools’ managing director Matthias Meyer, this configuration minimises vibration of the spindle and hence of the cutter for better component accuracy and increased tool life.
Four motor spindle options are available with speeds up to 18,000 rpm and torques up to 354 Nm. Heller says that the lift-and-swivel tool changer has two NC axes for short idle times and consistent operation. Chain-type tool magazine capacities are: HSK-A63 with 54, 80 and 160 pockets; or HSK-A100 with 50, 100 and 150 pockets.
For further information www.heller.biz

Fabricator opts for heavy-duty machine

CSI Aluminium has chosen a Tekna TKE 944-7 four-axis heavy-duty machining centre for its Hull factory, supplied and installed by Emmegi (UK).

Having been a satisfied Emmegi customer for nearly 20 years, the company had no hesitation in approaching Emmegi again when it needed a new large-capacity machine with a 7-m bed.
As a specialist glazing and cladding fabricator, CSI Aluminium has developed its own bespoke unitised curtain walling system for installing on sites with limited access. This system, which uses large 7-m sections of Aluprof profile, has advantages for city centre sites because it can be installed using a tower crane.
The team at Emmegi proposed the Tekna TKE 944 machine as the perfect solution for CSI because it has the large machining capacity required at the right price point and can link easily to the rest of the Emmegi machines in the factory.
Emmegi’s Tekna TKE 944 is a four-axis machining centre with a mobile gantry and 8 kW high-torque electro-spindle suitable for the heavy-duty machining of large sections of aluminium. The spindle moves along the A axis, allowing machining through a full 180° around each section. A clamp unit ensures correct positioning of the sections. Also featured is a 12-piece tool magazine mounted on the gantry.
Steve Bird, production manager at CSI, is pleased with the company’s investment in new Tekna 944: “The machine is doing all that Emmegi promised and is already helping us to deliver on a new £3.5m contract for our unitised curtain walling system in central Manchester.”
For further information www.emmegi.com

Trio of machines installed at subcontractor

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has supplied three new Doosan vertical machining centres to Portsmouth-based precision subcontract specialist, Penta Precision Engineering Ltd. The three machines are all Doosan DNM 4500 models.

Says Edward Moss, Penta Precision’s technical account manager: “We constantly audit and review our operational efficiency and effectiveness as part of a company-wide continuous improvement programme. As a result, we identified that some of our older machine tools were experiencing reliability issues and causing production bottlenecks. It became clear that, to help alleviate these problems, we needed to invest in new high-performance machines.
“Doosan’s DNM series of vertical machining centres are popular, proven and have a good reputation in the market,” he adds. “Having contacted Mills, we visited their facility in Leamington to see the DNM machines, and to discuss our requirements in more detail. We were impressed with their approach and by the aftersales service and support they provide to customers.”
The three Doosan DNM 4500 machines supplied to Penta Precision are all equipped with a 10.4” console, Fanuc 0iMF control (with 200 block look-ahead function), BT40 direct-coupled 18.5 kW/12,000 rpm spindle (117.8 Nm), 30-position ATC and linear guides on all axes.
In addition to the standard specification, Penta Precision also requested Renishaw spindle probes and Filtermist oil/mist extraction units on all three machines, and a Nikken rotary table on one.
“Since being installed the three DNM 4500 machines have been working flat out,” says Moss. “Our investment in Doosan machine tools from Mills CNC is having a positive impact on our productivity, performance and profitability.”
For further information www.millscnc.co.uk

Battle robots get a five-axis boost

For followers of the BBC’s Robot Wars programme, the names Sir Killalot, Shunt, Matilda and Dead Metal will be familiar as the house robots whose sole purpose is to lie in wait for competing bots and take their opportunity to destroy them.

These mean weapons are designed and built by two brothers in a small corner of their family business that is more used to manufacturing furniture castors.
Grant and James Cooper both worked for the family company of Priory Castor and Engineering in Birmingham, but as that business changed they saw a need to diversify and put their knowledge of engineering design to good use. The result was Robo Challenge, a design and creative engineering company that now works alongside TV production companies to create one-off robots and engineering concepts.
Robo Challenge employs an XYZ LPM vertical machining centre to create a range of parts from aluminium, titanium and stainless steel.
“We tend to be at the end of the process after weeks, if not months of discussion have taken place,” says Grant Cooper. “We are then asked to produce complex machines in a short space of time. For example, the four house robots for Robot Wars were designed and built in less than eight weeks, but typically we get one to three weeks to complete a project, so an efficient machine that can be used by anyone here was essential for us. The LPM with its ProtoTrak control, tool changer and large table, works perfectly for us, especially as just about everything we produce is a one-off.”
For further information www.xyzmachinetools.com

Dyson cleans-up with new machining centre

Founded almost 100 years ago, Milton Keynes based Dyson Diecastings Ltd initially started as a casting business, although nowadays the company offers a multitude of services, something that is supported by the recent acquisition of a Fanuc Robodrill B-series machining centre.

“As technology has evolved, so have customer demands and the capabilities of our company,” says director Paul Savage. “We have moved from just drilling and tapping to adding a CNC machining department, and now conduct profile milling, facing and much more. In terms of value-added processes, we offer painting, plating and polishing for those who want a fully finished product.”
The Fanuc Robodrill B-series D21LiB5 features an extended bed length that accommodates the variety of components that pass through the machine shop at Dyson.
“Usually, we would go for a 1 m bed length machine and also have a 600 mm Fanuc machine alongside, but this 800 mm bed length Fanuc is ideal for what we need,” says Savage. “A key factor in selecting the B-series is that we bought a Fanuc Robodrill T21iF about six years ago and its reliability has been outstanding. Spare parts are sourced locally and the cost of running it has been kept very low. The B-series machine comes with a new interface while the spindle speeds and indexing unit all match what we’d been running previously. Programs transfer very simply and it ticks all the right boxes.”
For further information www.fanuc.eu