A chopper class like no other

When Daniel Twigden got the call to create his own class at the Manteca Adult School in Manteca, California, he organised one of the few chopper building classes in the country to his knowledge.

“We teach you how to build rigid frame choppers, like a 1948 Panhead, and other traditional style motorcycle frames,” says Twigden.

A passionate metalworker, Twigden says that passing along his knowledge gives him true fulfilment in his industry. And the skills he shares provides his students with a chance to learn a metalworking craft that brings both joy and potentially income down the road.

In the shop at Manteca, visitors will see a range of Baileigh Industrial machines contributing to the learning environment.
“As a class, Baileigh tools enables us to expedite the process,” says Twigden. “You can do all of these same tasks by hand with hand tools or tools that aren’t set up for volume manufacturing. So, having these big tools just enables me to teach what would take weeks, in days, and what would take months, in weeks. Really, it’s invaluable as a teacher to have these tools.
Specifically, Twigden calls his Baileigh RDB-175 tube bender the backbone of the chopper class, with its ability to cut all of the tube bending down from a week or so to just a few lessons.

The Manteca shops also feature an SH-12010 sheet metal shear, SR-5016 slip roll, HSP-66M-HD hydraulic press, and an BB-9610H heavy-duty hydraulic box and pan (finger) brake.

“Across all the campuses here at Manteca Unified School District, we’ve found Baileigh is one of the most reliable tools out there,” concludes Twigden.

For further information
www.baileigh.com

Kitamura takes centre stage on Dugard stand

A Kitamura MedCenter5AX 5-axis vertical machining centre will take centre stage on the stand (G260) of Dugard. With X, Y and Z-axis travel of 254 x 330 x 330 mm over a 170 mm diameter table, the machine incorporates a 30 to 30,000 rpm spindle with an HSK-E40 spindle taper that connects to a 40-tool ATC which can change tools in just 1.5 seconds. Rapid traverse is 60 m/min, while table rotation is 200 rpm in the A and C axes.

With linear and rotary scales, 67 million pulse encoder technology and 16 mm pitch ballscrews, Dugard says that the Kitamura MedCenter5AX is an extremely precise and productive proposition. Furthermore, with a positional accuracy of ±2 µm across the full stroke and repeatability of ±1 µm, the company is keen to point out that the machine is also one of the most accurate on the market.

For further information www.dugard.com

AUTOMATED ROUND-THE-CLOCK MACHINING OF PRISMATIC MEDICAL PARTS

At the Redhill factory of contract machinist ATC, the high quality, accuracy and repeatability of the medical devices it manufactures have been raised even further by the installation of a new, robotically loaded and unloaded production cell. Comprising a C12U five-axis machining centre served by an RS05-2 robotic billet handling system, it was built by the German firm Hermle and supplied by sole UK sales and service agent Kingsbury.

Guy Lord, owner and managing director of ATC says: “We’re one of the highest quality machine shops in the world, specialising in producing difficult components that others are unable to tackle. Around 95% of our turnover is medical work and we also manufacture super-accurate bearing rings. Currently, 60% of our business is from companies that have previously tried another subcontractor, either in the UK, mainland Europe or the US, and have been unable to obtain the quality they need.”

It is against this background that Lord decided to invest in the automated Hermle cell, which is allowing him to differentiate his company even more from the competition. At the end of January 2021, the subcontractor started manufacturing the products for which the equipment was bought, namely extremely complex spinal implants machined to ultra-tight tolerances from tough cobalt-chrome, whose low thermal conductivity tends to wear tools quickly. Surface finish is also extremely high to meet the cosmetic requirements stipulated by the customer.

This particular medical contract requires the production initially of a family of four different parts, with more to come, in cutting cycle times of approximately one hour. It takes just 30 minutes to change over between batches to make a different part, despite the complexity of the cell. Actually, the time to produce a first-off part, check it and very occasionally make adjustments has to be added to the set-up time.

The presence of the internal robot, temperature compensation within the C12U and integration of Blum tool wear monitoring with automatic sister tool change have allowed unattended production to continue day and night and throughout the weekend. It has lowered manufacturing cost-per-part and is delivering high levels of efficiency and consistency of output. A mix of different billets can be loaded into the cell on Friday night and the machine runs unattended throughout the weekend. Staff return on Monday morning to find a rack full of completed components ready for assembly or dispatch.

In March 2020, Kingsbury helped ATC with the urgent supply of a Hermle five-axis production centre equipped with an external, third-party, machine-tending robot to make ventilator parts for the NHS. It worked well, but Lord and his team realised that the configuration was overly large for the subcontractor’s general requirements. It was also apparent that billet loading and unloading of the finished components would work better and faster with a built-in robot.

“Cycle times in the new Hermle cell are broadly similar to those in other machining centres on our shop floor, some of which are automated with a pallet change system,” says Lord. “The benefits of robotic billet handling over manual intervention are consistency of component quality and dependability of throughput, added to which the cell runs 24/7 virtually unattended, unlike those that depend on pallet exchange.”

He went on to suggest that Hermle is one of the best global manufacturers of five-axis machining centres, while the addition of the integral robot really makes the installation “sing”, helping to amortise the investment much quicker than would otherwise be the case.

The plan is to take the automation a stage further within the next couple of years by integrating a co-ordinate measuring machine (CMM) into the cell so that each part manufactured is transferred to the metrology platform by the robot to have its critical dimensions checked. Offsets will be sent automatically to the machine control to keep components reliably within their tight tolerance limits.

Speaking of ATC’s relationship with the supplier Kingsbury, Lord says: “There are fewer and fewer really good machine tool agencies in this country and for us, Kingsbury is one of the best. It is down to the high-quality equipment they sell and the very good service they provide at all levels. We have been buying from them for over 60 years, initially from the company founder, George Kingsbury.”

He continues: “Whenever we have a problem, they are quick to respond over the telephone or send in an engineer, even during the lockdowns. As a mark of their ingenuity, they proved-out the RS 05-2 robot load system on our shop floor via a Teams meeting with engineers in the German factory, as it was the first such system in the UK.

“It is notable that, near the start of the first lockdown, we spoke to Kingsbury on a Friday and they supplied a Hermle machine on the following Tuesday. They sourced a robot from Germany quickly and set up the temporary production cell. It was a fantastic service.

“We will buy more machines from the same source when the next project requires one, or existing volumes increase, and you can be sure it will have a built-in robot.”

For further information
https://kingsburyuk.com/

Powerful yet easy-to-use software

Programming simplicity will be Hurco’s theme on Stand G200, where the company will be showcasing the latest software available on its proprietary Max5 control. Hurco says that the 19-inch colour touchscreen control is popular due to the ease of programming first-off parts. Among the demonstrations will be the latest ‘Solid Model Import’ option, which is capable of further reducing programming times. Whereas previously only 2D DXF files could be loaded directly into the control to create conversational data blocks, it is now possible to import 3D STEP files, including surfaces.

For further information www.hurco.co.uk

Making a stand for automation

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, will showcase its industrial automation and collaborative robot systems on Stand C160. Pride of place will go to a Mills CNC SYNERGi automated manufacturing cell, which comprises a new 10” chuck multi-tasking Lynx 2600SY lathe (with sub-spindle and Y axis) integrated with a Premier SYNERGi system.

The system includes an industrial robot, a large capacity and flexible part loading/unloading station, a part inspection conveyor, end-of-arm tooling, laser floor scanner technology, and a 17” touchscreen HMI powered by SYNERGi software. At Southern Manufacturing, the SYNERGi cell will demonstrate the significant productivity and operational efficiency gains that automation brings, and the way it can help manufacturers embrace lights-out operations.

For further information www.millscnc.co.uk