The MillTurn series of machines manufactured in Austria by WFL are used around the world to produce complex parts to high tolerances.

These components include compressor rotors, for which the company has developed a highly productive method for automated complete machining. A key component of this solution is the TC63-Digilog probe from Blum-Novotest, which is used to scan workpiece contours in a matter of seconds without the need to unclamp the workpiece from the machine.
The compressor rotor is made of GG60 grey cast iron, measuring around 400 mm long with an outer diameter of roughly 160 mm. By using special forming cutters, the rotor is turned and milled on an M40 MillTurn machine down to gauge-block standard in grinding quality. The machine does this automatically in a 24/7 operation, resulting in significantly shorter machining times.
Until now, grinding was required during the rotor manufacturing process because the necessary accuracy and surface quality could not be achieved by milling.
“Although the new process does not allow us to dispense with grinding in all applications, it is however sufficient that our procedure substantially reduces the amount grinding necessary,” explains WFL product manager Manfred Baumgartner.
During the finishing process, the workpiece is initially prefabricated to an excess of two-tenths of a millimetre. This contour is measured on the machine using the digital and analogue TC63-Digilog touch probe. Engineers can scan the entire circumference of the milled profile without unclamping the workpiece from the machine. In this way, the component’s geometrical accuracy and concentricity is determined “in double-quick time”.
From the resulting contour – which is shown on the CNC display – an algorithm calculates the optimum corrections for every tool engagement.
For further information www.blum-novotest.com

Mills CNC has supplied Cheltenham-based Ferrositi Ltd, a precision subcontract specialist, with a Doosan SMX 2600S turn-mill machine featuring a 13” quick-change chuck.

The machine was installed at Ferrositi’s facility in May 2020: a time when many companies were battening down the hatches due to COVID-19.
Making this investment during the height of the pandemic outbreak is typical of Ferrositi, as the company’s managing director Nick Furno points out: “Ever since the company was created in 2012 we have invested in multi-axis machine tools as a route to improving our productivity, operational efficiencies and competitiveness. We are always on the lookout to increase and strengthen our front-line machining resources.”
Despite the lockdown, such an opportunity arose in April 2020 and resulted in Ferrositi making its first investment in Doosan machine-tool technology and – coincidentally – its first turn-mill machine acquisition.
“Both Doosan and Mills CNC have good reputations in the market and, when I was informed that a turn-mill machine was viable immediately from Mills CNC’s stock at a competitive price, I was interested,” says Furno.
Having seen the SMX 2600S at Mills CNC’s Technology Campus facility in Leamington, the decision to purchase the machine was made.
“Already we can see, and appreciate, that the machine is powerful, fast, flexible and accurate,” says Furno. “We’re particularly impressed with its rigidity, ergonomic design and thermal stability. Using a single set-up, the SMX is capable of performing multi-machining processes. As a consequence, we can reduce production bottlenecks and limit stop-start operations.
“The SMX will help us consolidate and grow our position in existing supply chains and sectors, as well as helping to spearhead our move into new sectors and industries, such as the food processing and medical sectors.”
For further information www.millscnc.co.uk