ETG provides flexibility for HPC

Upon the formation of HPC Services Ltd in 1997, the company started with a single sliding-head turning centre. Since that point almost 25 years ago, the Ilkeston-based company has invested heavily in sliding-head turning technology for small part turning. However, for almost everything outside the dimensional realms of sliding-head machines, the subcontractor has put its faith in turning centres from Nakamura-Tome. Supplied and supported by the Engineering Technology Group (ETG), the Nakamura-Tome machines at HPC have provided productivity and flexibility for everything from simple to complex turning, as well as the machining of prismatic parts from bar.

“I think we bought our first Nakamura machine around 2003, and we’ve had them ever since,” recalls Paul Cobb, managing director at HPC Services.

Now with five Nakamura-Tome CNC turning centres on the shop floor, the subcontract manufacturer invested more than £600,000 in three machines between August 2018 and June 2019. The Nakamura WT100 and two WT150II machines followed the July 2017 arrival of a smaller Nakamura AS200 MY turning centre with live tooling and a Y-axis facility.

At that time, Cobb said: “As a subcontractor, you don’t know what is going to come through the door on any day, so these machines are perfect. We mostly use them for making mill/turned parts, on medium-sized production runs from a few hundred components to a few thousand, which is a real sweet spot for us.”

As part of the Hemlock Group of companies, HPC has more than 17 turning centres and 25 employees producing components for the industrial equipment sector. This includes fire-suppression equipment, printing machinery, scientific devices, packaging machinery, camera equipment and braking systems for the rail industry. The company typifies the subcontracting sector with its diverse workload, the variety of industries it supports and the expansive diversity of materials it machines and the services provided. With this thought in mind, the company has added yet another Nakamura-Tome turning centre, a WT150IIF model, which arrived shortly before Christmas.

Confirming why the Nakamura-Tome turning centres are so popular, Cobb says: “A few years ago Nakamura upgraded their older machines with new controls and much more rigid and powerful driven tooling. The machines were really good before, but now they have changed the game – and we simply had to invest in the new technology when it came out.

“As a business, we’ve built up our Nakamura models over the past couple of years, and the latest machine is testament to both the success we’ve had with the Nakamura machines and our investment programme,” he adds.

Before the investment drive in new Nakamura machines, HPC Services previously had the older models of the Nakamura brand.
“The residual value of these machines is unbelievable,” states Cobb. “We recently sold a Nakamura machine 13 years after we first purchased it, and we sold it for 50% of the purchase price. The loss you make each year really isn’t that much. It caused a problem when we sold the machine because we had written it down very low year-on-year so, when it came to selling the machine, we actually made a profit.”

Discussing the difference between the twin-spindle, twin-turret Nakamura-Tome WT100 and Nakamura-Tome WT150IIF, which both have Y-axis capability, Cobb says: “The WT100 is a smaller machine, making the kinematics and movement a little bit quicker.

However, it isn’t quite as versatile as the WT150II machines or the new WT150IIF, which has more power on the tooling stations. The other obvious difference is the bar diameter: we can get 46 mm diameter bar on the WT100 machine, whereas the WT150II machines can accommodate bar up to 65 mm.”

Continues Cobb: “The Nakamura machines have a lot of versatility and the ability to throw many driven tooling stations at the components. So, if you want to make fully milled parts with complete automation, you can. For example, it can be quite difficult to automate a machining centre, but if you can mill a prismatic component out of round bar, you are better off making the parts on a Nakamura machine. We do quite a lot of that type of milling work on the Nakamuras.

“Additionally, you don’t want to be putting your turned components on to milling machines after they have been turned, as it can knock all of your geometric relationships out. So, if you can make components in a single operation on a turning centre with all the complex milling and drilling, the quality of the finished part is far superior. Furthermore, the cost per component comes down as there is less handling of the parts.”

This is exemplified by the set-up of the latest Nakamura machines, which are all equipped with barfeed systems and a part accumulating Rota-Rack system from Hydrafeed. This configuration permits unmanned machining for upwards of 18 hours.

“The machines are also suitable for simple component runs,” says Cobb. “Our Nakamuras are very capable machines that do not take long to set up with the new control system, making them suitable for simple components. To make these machines justifiable on simple parts, we tend to do a minimum batch of 50 to 100 – that is our entry point for balancing productivity rates against set up times.”

Alluding to the flexibility of the Nakamura-Tome, Cobb states: “We have a really good team of people. This includes two or three highly skilled operators and a couple of apprentices, and they are all perfectly capable of setting these Nakamura-Tome machines. This gives our business the ability to switch components every day if we want.”

HPC Services has been delighted with the enhancements to the new models in the Nakamura-Tome range in terms of stability, rigidity and performance, but nowhere is this better emphasised than in the new Smart X CNC control panel. Working on a Windows platform, the FANUC-based control system introduces a multitude of innovations via a user-friendly and intuitive touchscreen interface. Some of the new technologies include a 3D Smart Pro AI system that automatically analyses CAD models to determine geometries, cutting tools and paths, as well as machining sequences. From this, a CNC program can easily be created to slash programming times and set-ups.

The Smart X system also introduces the NT Thermo Navigator, which uses AI-based machine learning to compensate for thermal growth, thus improving machine set-up and run times, along with precision. In addition, the CNC unit incorporates a simulation and overload function, the NT Work Navigator and an Industry 4.0 interface for complete connectivity.

Discussing the new format of the CNC on the Nakamura-Tome machines, Cobb says: “The old control systems were much more complicated. This new format has simplified the whole programming process, because a lot of it is feature orientated. So, if you are pocket machining or anything like that, there are many cycles built into the system and a lot of mathematical help to support you in working out dimensions and corners. As a result, you don’t have to use a CAM system. For everyday prismatic parts, the CNC control on the Nakamura is perfect.”

For further information
www.engtechgroup.com

Stäubli takes robots on tour in 2021

Stäubli has invested in a new robot demonstration vehicle, providing potential customers with a Covid-safe opportunity to see first-hand some of the latest developments in the company’s range. Among robots currently showcased within the vehicle include a collaborative TX2-60, which uses a combination of sensors and light guards to allow visitors to interact with the robot as part of a safe human-robot demonstration. A second showcase centres upon Stäubli’s TS2-40 SCARA robot for high-speed handling tasks. Customer visits are due to take place across the UK and Ireland in the coming months.

For further information www.staubli.com/en-gb

SafanDarley E-Brake Ultra at Fife

Glenrothes-based precision sheet metalwork manufacturer, Fife Fabrications, has invested a significant six figure sum in new technology as part of its ongoing growth plans. This investment in its fifth E-Brake press brake, the SafanDarley E-Brake 130-3100 Ultra, will further build its capabilities and services to facilitate future growth.

Installed in March 2021, the machine features lifting aids as a safety feature for managing larger panels and a bigger opening height to form taller flanges or parts. Like all E-Brakes, the Ultra will be fully integrated into the company’s ERP system.

Fife Fabrications’ managing director John Penman is pleased to be investing in new equipment to enhance and supplement its precision metalwork technology offering with the addition of the E-brake Ultra.

“Fife Fabrications has always been focused on continual investment in lean technology, people and ordering processes, which means we can provide the lowest possible overall cost to customers,” he says. “The timing of this investment will facilitate many learning opportunities for staff, trainees and apprentices at Fife Fabrications, offering clear benefits to our team, as well as to customers.

“The aim is to further build our capabilities and expertise, and continue providing customer service that is a cut above,” continues Penman. “It also supports our investment in developing young talent to further support the upskilling of young people in Fife. This helps to address the skills gap in our industry and in Fife more generally, as well as creating a pipeline of young talent for our business. Our investment in state-of-the-art technology from SafanDarley, with tooling from Wilson Tool, will ensure our services can move to the next level and increase our capability to design and deliver the highest quality products for customers.”

For further information
www.safandarley.com

Multi-beam folder at Bison

The new Morgan Rushworth EXR multi-beam folding machine is now installed in the Bison Machinery showroom for demonstrations and product trials. The EXR is said to be an extremely versatile folding machine fitted with a rotating top beam to allow both straight and box and pan folding, even within the same part.

The Morgan Rushworth EXR range of CNC folders features a rotating upper beam with one straight rail and one set of high divided tools that can both be utilised in the same folding program without any manual tool change. Such a versatile design enables high accuracy, high consistency and high productivity as there is only one initial tool set up to carry out. This configuration is suitable for many folding operations, including rectangular panel work with return edges to the four sides. The operator sets the program, folds the two long lengths with the straight rail, before the upper beam rotates automatically and the two ends are folded with the high divided tools.

The back gauge is integral to the rear support table, which is suitable for the folding of large sheets as the weight of the material is supported, resulting in a single operator performing traditional two-operator jobs. The standard 2D touchscreen CNC controls all upper beam clamping and rotating, folding beam and back-gauge movements, with an optional 3D touchscreen available to further assist the operator. Both controllers provide a view of the folded part, calculating whether the job is possible or not, the developed length and the bending sequence – including whether to turn material over or around.

Features of the EXR folding machine include: bending angle from 0-150°; 20° 1 mm sharp nose clamping beam rail with 25 mm clearance; 10 and 25 mm wide folding beam rails; and fast 1 m powered back gauge.

For further information
www.bisonmachinery.co.uk

Integration of bending and robotics

In 2015, Wesbart decided to carry out a full review of all products and manufacturing processes, which involved looking at every aspect of manufacturing to help improve productivity and reduce costs.

One of the main processes which required investment was folding. All aluminium and stainless steel parts were folded at Wesbart using a manual system with an operator. Due to an increase in orders it was necessary to use subcontractors to meet demand.

“Our production runs can range from 150 parts to more than 5000,” says sales executive David Patey. “We carried out some testing of various automation options and found the parts would need to be fed into the cell on a conveyor system. As a result, we contacted a locally based robot integration company [ICS Robotics and Automation] to work with Bystronic and develop a suitable system. We chose to use Kuka robots and the Bystronic Xpert 40 press brake due to their small footprint.”
ICS designed a bespoke space-saving set up using three Kuka robots, one operating each press brake with another feeding components from the conveyors. A camera system was included to identify the parts and confirm their correct placement on the conveyor.

The system arrived in January 2021 and has already shown a great deal of potential. According to Wesbart, the Bystronic press brakes are incredibly quick and reliable, while the user interface is very easy to operate, which helps expedite robot programming for the company’s components.

“With the investment made in the bending cell we hope to remain a market leader based on the quality, price and lead time of our products,” concludes Patey. “We also hope it will allow us to enter new markets.”

For further information
www.bystronic.co.uk