Small five-axis machine packs real punch

Mills CNC, the exclusive distributor of DN Solutions (formerly Doosan) and Zayer machine tools in the UK and Ireland, has introduced a new simultaneous five-axis machining centre.The DN Solutions DVF 4000 is the latest addition to the company’s best-selling DVF-series of five-axis machining centres and, with its compact size and technical specification, targets component manufacturers looking to improve their productivity and process efficiencies.

The DVF 4000 is powerful, fast, flexible and reliable, reports Mills CNC. It is suitable for processing parts that require multiple machining operations,reducing the number of set-ups required to produce such components to completion.The machine comes with a 12,000rpm (BT 40) directly-coupled spindle as standard, powered by an 18.5kW motor that generates 118Nm of torque. AFANUC 31i-Plus control enables machine shops to use the DVF 4000 in full simultaneous five-axis machining mode with advanced contouring capabilities.

Notably, the DVF 4000 is equipped with a 400mm diameter, integrated rotary tilting table with a zero-backlash roller gear cam design that delivers improved speed and reliability.
Productivity and process efficiencies are further realised with the machine’s 60-tool, servo-driven automatic tool changer and an integrated thermal compensation system, comprising six sensors strategically located within the machine that combat thermal drift issues in real time.

Roller LM guideways deliver improved speed and rigidity, while linear scales on the machine’s X, Y, and Z axes, and rotary scales on its B and C axes, ensure accurate positioning and repeatability.
For further information www.millscnc.co.uk

XYZ helps PJ Innovations make lots of dough

Market Deeping based PJ Innovations makes dough divider-rounder machines (and theirassociated spare parts) for the bakery industry. When the company formed in 2014 it subcontracted all component manufacturing requirements. However, PJ Innovations started investing in XYZ Machine Tools in 2016 to bring some of the work in-house.

The company’s first purchase was an XYZ Proturn SLX 425 lathe with ProtoTRAK control, which it uses for turning large shafts 90mm diameter and 1m long in batches up to 100.The Proturn SLX 425 is a gap-bed lathe with a capacity of 2m and swing over the bed of 480mm. The extra length gives options for longer shafts. Notably, the operator has 20-30 tools ready set, so switching between programs stored in the control unit takes just 5-10 minutes.

For frame plates and the many parts which require lots of drilling, tapping and boring, the company takes advantage of an XYZ SMX 5000 with ProtoTRAK control and 1930 x 356mm table. Programming takes place at the control and fast changeover between jobs makes this machine suitable for 1-offs and low batch sizes.

The most recent acquisition is an XYZ 1000 TMC with ProtoTRAK RMX control. Manufacturing manager James Goode says: “The tool changer speeds machining up a lot and the enclosed cutting area is better from a safety and cleanliness perspective. We also like the handwheels on all XYZ machines, which allow us to move backwards and forwards through a program to prove it out. You can easily learn to program the ProtoTRAK in one day.”

PJ Innovation’s new XYZ 1000 TMC is for component batches of up to 50-off that need drilling, boring and tapping. Additionally, tool setting is easy using the touch probe, with offsets recorded in the control by pressing the ABS set button.
For further information www.xyzmachinetools.com

Toolmaker gets right tool for the job

As a small subcontract toolmaking and machining business, Precision Engineering Services (Buxton) Ltd has carved a niche in the production of press and mould tools for the construction and DIY sectors. As part of these activities, the business undertakes a significant amount of wire EDM work, which is why it has just invested in a Mitsubishi MV1200S wire EDM machine from the Engineering Technology Group (ETG).

The Buxton-based manufacturer has a selection of manual and CNC machine tools as well as a die-sink EDM machine and a wire EDM. However, with the company’s 12-year-old Mitsubishi BA8 wire EDM being the busiest machine, its precision levels were sadly diminishing after more than a decade of non-stop operation.

“After more than 10 years of non-stop running, the ball screws on our existing Mitsubishi BA8 wire EDM were deteriorating and maintaining precision was becoming more of a challenge,” explains managing director Chris Barlow.“We knew that a new machine would be the best route forward. With linear drive technology and tubular shaft motors instead of ball screws, the new MV1200S has a 12-year accuracy warranty and an optical drive system that provides circular accuracy within 1μm, so we won’t have this concern in the future.”

With regard to overall cutting time, Barlowsays: “The speed of cutting is always restricted by the wire. However, features that would take four passes to finish on the BA8 are now possible in three or sometimes two passes with our new MV1200S. This improves our productivity by 25% and even 50% in some cases.”

This impressive productivity improvement is credit to the new V350 generator, which has a significantly higher effective clock rate.
For further information www.engtechgroup.com

Vollmer penetrates micro-tool market

Micro-tools are drills and milling cutters with diameters below 0.5 mm. Here, sharpening specialist Vollmer is successfully eroding these delicate PCD tools in a highly precise and cost-efficient way with its VHybrid 260 grinding and erosion machine.

Progress in areas such as medical implants and wearables means that electronic components are becoming increasingly fine and delicate, demanding the use ofever-smaller tools in the manufacturing processes. PCD micro-tools with diameters of 0.45 mm and below are in particular demand for the production of microchips.

The Vollmer VHybrid 260 grinding and erosion machine features Vpulse EDM generator technology, which achieves a surface finish of up to 0.05 Ra when eroding, corresponding to an average roughness of up to 0.24 Rz. In addition, it is possible to produce a cutting edge radius of up to 1.5 µm with the VHybrid 260. This capability eliminates the need for any subsequent grinding or polishing of functional tool areas.

To ensure optimum concentricity of 2 µmmaximum when machining micro-tools, the VHybrid 260 features an insulated tool steady rest, which also makes it suitable for eroding. Furthermore, due to the integrated‘Laser Check’measuring system, required tolerances of ±2 µm are achievable during fully automatic circular machining in a closed-loop process.

The VHybrid 260 is based on multi-layer machining, implemented through two vertically configured spindles. The lower spindle is forboth grinding and eroding. Moreover, the machine can switch up to eight grinding and eroding wheels, including coolant supply, fully automatically. Various automation options are available to enable unmanned operation around the clock.
For further information www.vollmer-group.com

New wire offers contamination-free erosion

To increase efficiency in the EDM production of contamination-free components, bedra has developed the confreecut ONE EDM wire.

In wire EDM, it is particularly important that component surfaces are free of contamination from foreign materials after production. In conventional wire erosion, the surfaces of the cut component may show residues of copper and zinc, requiring subsequent chemical cleaning. The additional cleaning process increases throughput times and production costs enormously. In the case of component surfaces that are difficult to access, the cleaning effect is also limited or insufficient.

Currently, most machine shops specify EDM wires made of molybdenum or tungsten for such applications. However, these wires carry a high material price. In addition, the wire guides are subject to heavy wear and automatic threading can be problematic, reports bedra.

To increase efficiency in the EDM production of contamination-free components, the company is introducing the confreecut ONE EDM wire, whichbedra says stands for contamination-free and fast machining with low wire guide wear and reduced wire costs. The wire has a high-purity outer nickel coating with optimal layer thickness. Run lengths of up to 60,000 metres per spool permit significantly more autonomous production compared with the usual fabrication of molybdenum and tungsten wires.

Notably, bedra was able to prove in numerous tests that confreecut ONE reduces the copper and zinc contamination, with zinc reduced to almost zero during processing with 2-4 trim cuts. In the process, bedra examined the components for these residues using highly sensitive analysis technology. The companyis happy to advise potential customers on specific erosion applications.
For further information www.bedra.com