A BREAK WITH TRADITION AT SUB-CNC

Mills CNC has recently supplied Sub-CNC Precision, a subcontract specialist based in Luton, with a new fixed-head multi-tasking lathe manufactured by DN Solutions. The machine, a compact FANUC-controlled Lynx 2100LSY equipped with a sub-spindle, Y axis and driven tooling, is providing Sub-CNC with a fast, accurate, flexible and reliable turning solution. It arrived at the company’s 15,000 sq ft facility in April 2023.

Established in 2008 by current co-directors Yian Stavrou and George Dingley, Sub-CNC Precision today employs 23 members of staff and is ISO 9001 certified. Over the past 16 years the company has grown exponentially and regularly makes strategic investments in its people, plant and equipment as part of an established and successful continuous improvement programme.

The Lynx 2100LSY is the first machine from DN Solutions acquired by the company in its 16-year history. Since installation, the machine has been put through its paces producing a range of small, high-precision and often complex components for a number of tier-one customers operating in the automotive, aerospace, defence and medical sectors.

Sub-CNC Precision machines from solid and from a wide range of materials that include aluminium, mild steel, stainless steels, titanium, brass and bronze. Batch sizes are typically up to 200-off with parts machined to tight tolerances in the realm of 50 µm and exacting surface finishes. At present, the Lynx 2100LSY is seeing use as a chucking lathe, although the imminent arrival of a 51 mm capacity bar feeder in the coming weeks will increase the machine’s versatility.

The bar feeder integration will also see the Lynx 2100LSY used to machine lower volume batch work processed currently on the company’s sliding-head lathes.

Says Yian Stavrou, Sub-CNC’s managing director: “The Lynx 2100LSY has been a great addition, improving our in-house machining capabilities. With its one-hit capabilities, the lathe is proving instrumental in strengthening our supply chain position, securing new business from existing and new customers in the UK and mainland Europe.”

The synchronisation of the lathe’s main and sub-spindle allows, via quick and seamless part transfer, the machining of component front and back ends in a single set up. The result is faster part cycle times, improved accuracies and increased work throughput.

Driven tool capabilities in conjunction with the machine’s Y axis enable the quick and efficient generation of milled and drilled axial and radial features, eliminating the need to transfer parts to a separate machining centre for finishing.

“Technology such roller-type LM guideways, a sub-spindle, Y axis and driven tools help deliver high accuracy, fast part processing times and improved process efficiencies,” says Stavrou.

Although the multi-axis Lynx 2100LSY has strengthened Sub-CNC’s machining capacity and capabilities, back in early 2023 the company was originally looking at a ‘simpler’ and more straightforward fixed-head lathe investment.

Recalls Stavrou: “We were initially in the market for a two-axis lathe that could undertake secondary reworking operations on selected parts that had already been machined overnight on our existing, production-oriented fixed-head lathes but which, for various reasons [typically broken or worn tools] failed to meet the required part quality standards.

The company knew of Mills and had a positive impression of the company, its machines and the aftersales service.

“We approached Mills CNC to see if they could identify a suitable machine,” reveals Stavrou. “It was Mills’ customer and visitor centre in Leamington where we were first introduced to the Lynx 2100LSY.”

Discussions with Mills technical and sales staff helped Sub-CNC clarify its new investment requirements, with the company duly opting for a multi-axis, multi-tasking lathe. This more sophisticated and higher specification lathe would still enable Sub-CNC to use it for reworking operations, as per the original intention. However, when not in use for such work, the Lynx 2100LSY would also provide the company with a high-productivity and flexible turning solution for producing low-volume high-precision parts in one hit.

Says Stavrou: “This, we decided, was the better option, and was one that would not only address the reworking issue but also provide us with an accurate, high-productivity lathe to handle new work.”

The fact that the Lynx 2100LSY was in already stock, with delivery and installation available in just a few days, was also a major selling point.

DN Solutions’ Lynx 2100LSY is a best-selling 6-inch chuck/51 mm bar diameter lathe with a 300 mm maximum turning diameter and a 510 mm maximum turning length. The machine features a 15 kW/6000 rpm/127 Nm main spindle, a servo-driven 12-position turret with fast indexing capabilities, driven tooling (6000 rpm), a ±52.5mm Y axis, a 5-inch chuck sub-spindle (5.5 kW/6000 rpm) and FANUC 0iTP control with 15” touchscreen.

The Lynx 2100LSY supplied to Sub-CNC also featured a parts catcher, automatic tool setter and Filtermist extraction unit.

“The Lynx 2100LSY has been a good investment,” states Stavrou. “It is fast, accurate and reliable, enabling us to secure new machining contracts from existing and new customers.

The decision to invest in a multi-tasking lathe as opposed to a two-axis model has been vindicated, with the Lynx 2100LSY making a positive contribution to our growth.”

He adds: “Delivering high-precision components to customers on time and in budget is what Sub-CNC is all about. We regularly monitor and benchmark our performance against KPIs and, where and when we identify areas for improvement, we act quickly and decisively to address them.”

In addition to investing in advanced machine tools and integrated automation systems, the company in November 2020 relocated to its current facility in Luton. Sub-CNC has spent considerable time and resources in modernising and kitting out the machine shop and its administration and office areas.

The facility features a discrete inspection facility in the machine shop and separate assembly/sub-assembly, packaging, distribution and raw material stock areas. The company has also recently invested in a sophisticated ERP system to automate, manage and streamline core business operations and processes in real time, thus improving efficiencies and productivity.

To address current and future skills shortages, the company operates a successful in-house apprenticeship programme in conjunction with a local college, and a trainee foundation programme for new employees.

Although primarily a precision turned-part specialist using a range of sliding- and fixed-head lathes, the company is always looking to grow and has recently invested in two machining centres and a grinding machine to fulfil a machining contract for a newly-acquired customer.

For further information www.millscnc.co.uk

Copper specialist grows manufacturing capacity

Metelec, based in Wolverhampton, is continuing its growth trajectory in added-value manufacturing by committing to a further circa £400,000 investment in cutting-edge machines that will increase its capacity and productivity. The company recently took delivery of an EHRT compact punching machine from Germany that effectively doubles capacity and complements the single-punch EHRT with 10 tool holders that arrived in 2021. 

The EHRT compact punching machine has three integrated multi-head tools, minimising tool changeover times with the ability to produce products in high volume. Moreover, software integrates manufacturing design management and production scheduling with the existing EHRT, which already covers Metelec’s full product range.

Metelec’s EHRT was the first of three recent machine investments. The company has since taken delivery of a Cosen G320 bandsaw, replacing an 11-year-old Cosen C320 to provide greater efficiency and productivity. In addition, June saw the arrival of an Amada EG-4010 electric press brake that increases the speed and range of products available from Metelec.

Steve Dove, operations director at Metelec, says: “We’re delighted to reveal our continued commitment to investment and growth with the purchase of these three industry-leading machines. Each offers different capabilities and benefits, but they all ultimately help to improve our quality, proficiency, precision, speed and capacity.”

Dove says there is huge potential for growth in copper, particularly around electric charging infrastructure and data management.

“Investments such as these will help ensure we lead the way in the production of switchgear components and kits of parts for years to come. Two big challenges facing the UK economy at present are growth and productivity. Here at Metelec we’re proud to be addressing both in our pursuit of manufacturing excellence.”

More information www.metelec.com 

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