Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has recently supplied high-end audio equipment design and manufacturing specialist, Linn Products, with a customised SYNERGi automated manufacturing cell.

The state-of-the-art cell, installed at the company’s 7200 sq m facility in Glasgow, represents a significant investment for Linn and comprises a new Heidenhain-controlled Doosan DVF 5000 five-axis machining centre and a Fanuc six-axis industrial robot with 45 kg payload. Other features include an integrated racking system that holds up to 24 standard size pallets, 2 m high safety caging/fencing and a 17” touchscreen HMI driven by Mills’ proprietary SYNERGi software. The cell is already running unattended overnight and at weekends

“Our high-end products are machined from solid aluminium,” states director of operations Chris O’Brien. “Product interiors are ‘hollowed out’ and feature a number of chambers, separated by thin walls, where electrical and electronic components are housed. We machine product exteriors to a mirror finish using a large diameter fly cutter that face mills the entire surface in one pass to produce a uniform finish.”

He continues: “We rely on our Doosan machining centres to deliver fast and accurate material removal rates and super-fine finishes. Metal removal on premium products can be in excess of 80%, while part cycle times, owing to roughing, semi-finishing and finishing operations, can take several hours to complete.

“The DVF 5000 machine is a proven performer. It is fast, accurate, flexible and reliable. When in automatic mode the machine’s side door is used, but we can also use it in manual mode via the front door. This means we can use the DVF 5000 as a stand-alone machine when required.”

For further information
www.millscnc.co.uk

The European Space Agency’s Rosalind Franklin Rover is due for launch from Baikonur, Kazakhstan in summer 2022, with a target to land on the surface of Mars in March 2023. Once there it will set about identifying signs of water-rich minerals, which could indicate past life. Key to these investigations will be the optical bench which, as the ‘eyes’ of the rover will contain two stereo cameras, a mono high-definition camera and array of electronics. Known as the ‘Pan Cam’ this device was developed and manufactured by the Mullard Space Science Laboratory, the home of UCL’s Department for Space & Climate Physics.

The optical bench comprises a box with separate top and bottom, machined from 5083 grade aluminium, which are joined together using electron beam welding techniques. Machining was completed at the laboratory’s workshop in Surrey using an XYZ MiniMill, the smallest vertical machining centre available from XYZ Machine Tools.

Due to the complex design, there were some extremely fine details to machine, such as an O-ring groove around the lid, measuring just 0.35 mm wide, as well as numerous M1.6 threaded holes.
The success of this project convinced Simon Hemsley – head of the mechanical workshop – of the value and flexibility provided by machining centres with tool-change capabilities. So much so that an order has just been placed for an XYZ 500 LR linear rail vertical machining centre. This machine, which has been part funded through the Government’s Research Capital Investment Fund, comes with the latest Siemens 828D control featuring the optional advanced programming software package that includes ShopMill technology.

For further information
www.xyzmachinetools.com

Royston-based DGF Engineering Ltd has recently bought its first CNC machining centre from Dugard. The subcontract manufacturer works with customers to undertake everything from design and consultation through to prototypes, small batches and production-run machining.

With the three-axis machining centre marketplace being extremely competitive, Liam Fernard, son of company founder, explains why the business opted for the Dugard 1000 machine with its Mitsubishi M80 CNC and capacity of 1050 by 640 by 660 mm: “Firstly, we wanted to move away from our current supplier, as we weren’t particularly happy with the service. With regards to the Dugard machine, it’s robust, durable and ticked all the boxes. We do quite a lot of large workpieces, so the 1 m bed is perfect. In addition, the training from Dugard was excellent and really comprehensive.”

The Dugard 1000 will machine parts for sectors such as scientific and laboratory equipment, gas analysis and chemical detection, and telecommunications and optical fibre, as well bespoke components for the automotive and agriculture industries.

Like any subcontract business that frequently undertakes repeat work, DGF Engineering was asked if transitioning parts from one machine to the new Dugard 1000 with the Mitsubishi M80 CNC would be an issue.

“There have been no problems whatsoever,” says Fernard. “There might be compatibility changes that we may need to make with existing programs, but they are very small tweaks. The programs will be as they are on any other machine. I was initially dubious about the touchscreen control, especially in the engineering environment with dirty fingers, but it works really well and makes things a lot easier.”

For further information
www.dugard.com