Dugard offers blueprint for success

Although only founded in 2004, the directors at Machfab Engineering can offer more than 60 years of manufacturing expertise in all aspects of machining, sheet metal and fabrication. But regardless of experience, everyone can learn new tricks – and for this Birkenhead-based company, the learning curve has taken a new twist with investment in 3D printing and CNC machine tools from Dugard.

Servicing customers in sectors as diverse as automotive, aerospace and offshore, through to petrochemical, pharmaceutical and food, Machfab offers a complete service portfolio that includes conventional and CNC milling and turning, jigs and fixtures, breakdown and repair work, press tool manufacture, reverse engineering, prototyping, R&D, and sheet metalworking. Some of these services were not previously available.

As Machfab Engineering director Ian Hazlehurst says: “Two years ago, we had the idea to diversify the company. We’ve always predominantly been a conventional machine shop and we wanted to get into CNC machining – but we had to offer something different to everybody else. So, we went down the 3D printing route to get into additive manufacturing. We worked with the Liverpool Innovation Fund and managed to get funding from them to purchase our first 3D printer.”

The company bought a Stratasys Fortus 380mc. Explaining the reason for buying the machine, Hazlehurst continues: “We bought this machine primarily to get into prototyping for R&D work. However, if we got a project that needs final production parts, we would never be able to offer the service to manufacture those components, which is why we invested in CNC machining – to offer customers the full package.”

Another reason the company opted to invest in CNC machine tools was that it was not always competitive on batch work or small production runs of components.

“We weren’t competitive on volume work as everyone has CNC machines and we had conventional machines, which meant our production times were a lot longer,” explains Hazlehurst. “So we decided – as part of the project with the 3D printer – to invest in two Dugard machining centres.”

The subcontract manufacturer simultaneously purchased a three-axis Dugard 1100 machining centre with a rotary table and a Dugard 1000E machining centre.

“The story behind the 1000E is that Dugard actually gave us the machine as a ‘test model’ as we had initially decided to buy the larger Dugard 1100,” says Hazlehurst. “The Dugard 1000E machine was installed for our guys to learn on – and we liked the machine so much we bought it, as well as the larger Dugard 1100 machine.”
For a company that had not yet stepped into the realms of CNC machining and had a history steeped in conventional machining, the initial loan of a CNC machining centre to prepare it for CNC production goes a long way to demonstrate the service provided by Dugard Machine Tools.

Referring to the larger of the two machines and why the company chose the Dugard 1100, Hazlehurst recalls: “We wanted a solution that gave us the diversity of components that we could put on the machine. We’ve installed a 4th axis unit so we can offer additional services and flexibility. We also have a Renishaw probing system, which means we can take measurements of parts before we remove them from the machine – as certain customers asked if we could do that. Equally important is the fact that the machine has a large bed and a powerful spindle, where we can take large chunks of material off. And we can machine hard steels as well.”

The Dugard 1100 VMC provides a work envelope of 1100 x 610 x 560 mm in the X, Y and Z axis respectively, with a 1000 kg maximum table load accommodated on the 1250 x 600 mm bed. A 20 to 10,000 rpm speed capability guarantees high levels of torque throughout the speed range.

Complementing this attribute is the 24-position automatic tool change carousel and the BT40 spindle taper that permits heavy-duty cutting on a complete range of materials, including challenging aerospace-grade metals. Furthermore, both machines supplied to Machfab include a Siemens CNC, although FANUC and Mitsubishi options are also available to suit end-user requirements.

The Dugard 1000E that was initially installed as a ‘test model’ is a cost-effective VMC with similar characteristics to the Dugard 1100 VMC, which is why the company opted to keep the trial machine alongside the larger 4th axis Dugard 1100.

“Now we have the Dugard machines, we know we can make the parts and make them right,” concludes Hazlehurst. “The machines also make us competitive, so we pride ourselves on the fact that we know our pricing will be right and we will deliver on time. Our customers will always get exactly what they ask for.”

For further information www.dugard.com

Floyd ups pressure for sliding-head lathes

Floyd Automatic Tooling has added the new Precitronics TOHP series of driven tooling with integrated high-pressure coolant feed to its portfolio. The new TOHP system offers through-coolant delivery up to 135 bar for driven tools and applications on sliding-head turning centres.

Available now, the Precitronics TOHP range of driven tooling is suitable for use on all types and makes of sliding-head and fixed-head machines fitted with a high-pressure coolant pump. Connecting the variety of live tooling configurations to the machine tool and the external high-pressure coolant pump is facilitated by a selection of quick-change connectors from the HEB range of locking and connecting plugs, flexible and rigid fluid distribution tubes, distribution blocks, connectors and adaptors – all available from Floyd Automatic.

In the work envelope, the Precitronics system is available for all spindle types with configurations such as ER, ER-A internal collets, CAPTO, KM, HSK, DIN, Weldon, MMT and ABS Komet. The flexibility of the system also extends to the drive connection, which can connect to all types of tool connection.

From a flexibility perspective, options for the Precitronics TOHP include an axial system, axial offset, axial speeders, radial double output, radial 90° system, radial 90° speeder, fixed angle, radial adjustable, axial multiple spindles, radial multiple outputs, polygon maker, thread whirling, gear hobbing and radial Y-axis – all of which can be configured to the specific turning centre.

According to Floyd Automatic, cycle time reductions of up to 30% are achievable by delivering high-pressure coolant directly to the cutting edge. Many of the systems also incorporate an additional coolant nozzle that simultaneously delivers cutting fluid to the shank of the tool, as well as the cutting edge, significantly improving cooling and swarf evacuation.

For further information
www.floydautomatic.co.uk

Metal-forming strength at EMO Milano

The Metal Forming Committee of UCIMU-Sistemi per Produrre, the Italian machine tool, robots, automation systems and ancillary products manufacturers’ association, has expressed its unanimous decision to take part in the next EMO Milano 2021, which takes place on Fieramilano on 4-9 October 2021.

Filippo Gasparini, vice-president of UCIMU, says: “After almost two years of absence from exhibitions due to the pandemic, we have chosen EMO Milano 2021 as the first stage to present our product offering to the public. In doing that, we are convinced that this event will offer us interesting business opportunities and, at the same time, contribute to strengthening the role of Italy in the sector.”

For further information
www.ucimu.it
www.emo-milano.com

Hull subcontractor selects Victor

Hull-based Rubitec Engineering Ltd has recently purchased a Victor Vturn NP20 CNC turning centre from GM CNC Machine Tools, the first Victor machine on site.

Andy Shores, managing director of Rubitec Engineering, says: “The machine has cut our run times and it’s a nice feeling to have a level of support from GM CNC that ensures with just one phone call, we can have everything we need.”

Commenting on why the company needed the Victor Vturn NP20, Shores says: “We had an ageing turning centre of similar capacity and capability to the Victor, but it was unreliable. And even though we service a lot of our own machines, the maintenance costs were escalating. We needed a new machine with a compact footprint and Victor fitted the bill.”

Looking closer at the specifications of the Victor Vturn NP20, it has a 52 mm through-spindle bar capacity. However, with the slant bed construction, the turning centre offers a 650 mm swing over the bed, providing 320 mm maximum turning diameter.

“The stability and kinematics of the Victor Vturn NP20 have increased productivity by at least 20% compared to our other machines,” says Shores. “In addition, the rigid tool turret and powerful coolant supply have improved the tool life on our milling tools by over 30%, while the overall machine construction has also helped to increase tool life for turning tools by 30%.”

Concluding on the service from GM CNC, Shores says: “To provide a score, I would certainly give GM CNC 10 out of 10. We trust GM CNC, its staff and levels of service implicitly.”

For further information
www.gm-cnc.com

Positivity from subcontractors

The UK’s subcontract manufacturing sector is emerging from lockdown with exceptionally strong sales pipelines, according to a cross-section of industry leaders. For instance, Chris Shield at Leicester-based Shield Group, says: “The pipeline is very strong and we’re feeling a lot more positive compared with six months ago.” Andrew Whitham at Manchester-based Brooks Ltd agrees, adding: “We’ve enjoyed a period of sustained growth and investment despite the challenges of COVID and lockdowns…the order book is very strong.”

The story is similar at Stoke-based John Hyde Engineering. “We’re more positive than six months ago and the pipeline is looking increasingly robust,” says John Hyde. Alan Mucklow, managing director UK and Ireland sales and service at Yamazaki Mazak, says the optimism of the subcontracting sector is a much-needed boost for UK manufacturing. “It is very striking, when I talk to customers, how positive the outlook is.”

For further information
www.mazakeu.co.uk