EDITORIAL ROUNDUP

Living and breathing continuous improvement

GF Machining Solutions has recently supplied two high-performance Mikron machining centres with Heidenhain controls to Mechlam Precision Tooling, a precision mould tool, fixturing and subcontract manufacturing specialist based in Haydock.

The new MILL E 700U simultaneous five-axis machine, equipped with an integrated seven-station APC, and the new, large-capacity VCE 1200 Pro three-axis machining centre are major additions to Mechlam’s 8000 sq ft facility.

The machines are now being put through their paces producing a range of complex, high-precision parts that include intricate components for mould tools. Materials machined include aluminium alloys, tool steels, stainless steels, Inconel and plastics.

A hallmark of Mechlam, and one that helps explain the company’s continuing success and the strong position it occupies, is the quality of the parts it is able to machine: exacting tolerances of ±5 µm and surface finishes down to Ra 0.2 µm are the rule not the exception.

Explains Martin Atherton, Mechlam Precision Tooling’s owner and director: “We’ve always invested in GF Machining Solutions’ technology. The machines are reliable, represent great value and deliver the accuracy, repeatability and surface finish we require, and our customers demand.

“The MILL E 700U gives us simultaneous five-axis machining capabilities which enables us to machine complex and intricate features and details on mould tool parts and precision components that cannot be achieved, quickly or easily, using 3+2 operations,” he adds.
“Furthermore, because we can machine parts to completion in a single set up on the MILL E 700U, processing times are reduced, production bottlenecks are avoided, accuracy is maintained and customer lead times are more easily met.”

The productivity and efficiency gains delivered by the MILL E 700U have been amplified with the integration of the workpiece pallet changer.
For further information www.gfms.com/uk

Process-safe five-axis machining

With the DMU H monoBLOCK series, DMG Mori says it has successfully implemented its customers’ requirements for flexibility, process reliability and automation. Now, the machine tool manufacturer has released the new DMU 85 H monoBLOCK and DMC 85 H monoBLOCK as a consistent expansion of the series. The new size aims in particular at users from the mechanical engineering, mould and die, aerospace, and semiconductor sectors.

Thanks to the optimised chip fall, horizontal five-axis simultaneous machining allows absolutely process-reliable production of complex workpieces. In the case of the DMU/DMC 85 H monoBLOCK, travels of 850 x 1150 x 900 mm serve a wide range of components. The long Z-axis travel makes this size suitable for deep-hole drilling.

The swivel rotary table, which is mounted on both sides, can support a load of up to 1000 kg (800 kg for the version with pallet changer). It can be used for five-axis machining of individual parts, as well as series components on clamping towers. A solid basis for precise machining is provided by the inherently rigid machine bed, the horizontal gantry concept, the thermosymmetrical design and the integrated cooling concept. Linear drives in the X and Z axes, and a direct drive in the C axis, also ensure maximum dynamics, while speedMASTER spindles facilitate high-speed applications.

To increase productivity, the DMU 85 H monoBLOCK and DMC H 85 monoBLOCK can be automated according to customer specifications – both for individual parts and in series production. For the former, for example, the new PH Cell 2000, a retrofittable handling system for up to 21 pallets and workpiece diameters up to 1100 mm diameter, is available.
For further information www.dmgmori.com

Four-machine FMS meets rising demand

A major supplier of aerospace parts in Italy is counting on a Starrag-developed flexible manufacturing system (FMS) to deliver exceptional machining rewards and reduced piece-part costs. Once commissioned, the four-machine, minimally-manned automated solution will operate around-the-clock to meet rising demand for aero-engine components.

Based on a quartet of Heckert HEC 500 X5 multi-axis machining centres, each featuring a five-axis trunnion-type table, the FMS will be served by an integrated pallet system and a centralised tool storage facility that will house 2000 tools to cover all eventualities in the single set-up, multi-task machining of the family of parts.

In addition to highly efficient cutting and cycle times, the Heckert machining centres will also ensure high-accuracy cutting – to within 2-3 µm – of the titanium and high-alloy steel workpieces which range in size up to 500 x 500 mm.

These systems may contain varying Starrag Group machines plus the integrated technologies of, for example, workpiece handling/holding and transport, cell control and tool storage systems, as well as complementary processes such as grinding, deburring, component cleaning and finish inspection.

In this case, the HEC 500 X5 machining centre was the optimum choice in terms of specification and performance. Not only does the machine’s XYZ envelope of 1000 x 800 x 1000 mm (and 800 kg capacity 500 x 500 mm pallets) meet all workpiece size demands, but the up to 82 kW/1500 Nm/15,000 rpm/65 m/min (rapid traverse rate) spindle also provides the required power and cycle time capabilities. Additionally, the machine’s B axis can rotate 360° at 80 rpm, while the A (swivel) axis operates at -45° to +91° at 15 rpm to enhance the machine’s multi-axis capabilities.
For further information www.starrag.com

XYZ mill boosts time-critical deliveries

Seal Team Systems creates bespoke leak repair systems for customers such as food manufacturers, energy generators, water suppliers and hospitals. The on-site leak sealing technology minimises any disruption or downtime, which can be expensive or life threatening. Time is therefore critical in manufacturing a range of components that combined can create an effective leak repair which can be made permanent at the next scheduled maintenance shutdown.

With every on-site leak posing different problems, the parts manufactured by Chesterfield-based Seal Team Systems are bespoke. The process starts with a customer site visit by a trained technician who reviews the problem and takes detailed measurements. Manufacturing starts upon the technician’s return to the factory. All of this can take 2-3 days, a situation compounded by a reliance on manual machining. To address this situation, Seal Team Systems has invested in an XYZ RMX 5000 bed mill fitted with the latest ProtoTRAK control system.

“We recognised a need to automate the process as much as possible, especially as finding the skilled people to create the parts we need was becoming harder,” says Andy Mills, director at Seal Team Systems. “With the XYZ RMX 5000, the technician, who was also the machinist, can now simply text all the details to us and we can start machining straightaway, turning what was a 2-3 day process into a next day service.”

Ken Black, director at Seal Team Systems, adds: “The move to the RMX 5000 with the ProtoTRAK control was a logical step up from manual machining, the training was straightforward, and we were operating it very soon after installation. The time savings we are making are significant, and typically amount to a 66% reduction in lead times.”
For further information www.xyzmachinetools.com

Telsonic UK doubles space

Telsonic UK has doubled the size of its Poole facility to meet increasing demand for its ultrasonic modules, systems and automated solutions. The additional 2400 sq ft of floor space, which incorporates another 325 sq ft conference room, is now fully operational. Furthermore, the additional floor space makes it possible for the company to maintain the best possible working environment, which in turn fosters the highest levels of both quality and performance. The space also provides extra space for new staff offices, customer meeting rooms and storage.
For further information www.telsonic.com