When JEB Precision won an order to manufacture a complex component for an aerospace air handling system, the Northwich-based subcontract manufacturer recognised that its existing production method required an upgrade in order to improve productivity. The solution arrived in the shape of a Nakamura-Tome AS200L-MYS turning centre from the Engineering Technology Group (ETG)
The S130 grade stainless steel parts were required in batches of more than 100 per month, but the existing five set-up process on multiple machines was an unsustainable long-term solution.

With six turning centres from ETG on-site, JEB Precision was already familiar with the extensive solutions available, but this was to be the first Nakamura-Tome machine.

Discussing the project, JEB operations director Michael Bebbington recalls: “Although our Hardinge turning centres are very capable machines, the Nakamura-Tome AS200L-MYS is a twin-spindle machine with milling capability and Y-axis machining that is built on a very robust platform. By investing in this technology, we were immediately able to reduce set-ups, increase throughput, improve process reliability and quality, and free capacity on our other machine tools.”

Before the arrival of the Nakamura-Tome AS200L-MYS CNC turning centre, the 83 mm diameter by 23 mm aerospace part demanded an extensive seven-hour set up time across several machines, although the combined cycle time was only 30 minutes.

The Nakamura-Tome AS200L-MYS at JEB Precision features a Hainbuch collet chuck in the main spindle and a Hainbuch expanding mandrel on the sub-spindle for ID clamping to ensure complete machining in a single operation. The part is machined complete in just 20 minutes on the Nakamura-Tome AS200L-MYS and, in the early days of gaining familiarity with the twin-spindle workhorse, JEB had slashed 30% off its programming time, a figure that is destined to improve as the company enhances its understanding of the machine.

For further information
www.engtechgroup.com

A collaboration between CAM software component provider ModuleWorks, cutting tool manufacturer Sandvik Coromant, and HCL Technologies, creator of CAMWorks, has produced one of the first commercial implementations of the PrimeTurning methodology in a CAM system.

Invented and patented by Sandvik Coromant, PrimeTurning increases machining efficiency by offering turning in all directions. Sandvik Coromant worked together with ModuleWorks to implement the PrimeTurning method as a software solution that can integrate into any CAM system. With support from ModuleWorks, HCL Technologies has now integrated this solution into CAMWorks, offering PrimeTurning as a native CAM strategy for improving efficiency and job throughput in machine shops.

The PrimeTurning method enables CAMWorks to achieve faster material removal rates and higher productivity than with conventional turning methods. ModuleWorks also developed optimised G-code generation for PrimeTurning with versatile parameterisation. Integrated into CAMWorks, this delivers fast and flexible job set up for the diverse range of CoroTurn Prime turning tools.

Julia Meyer-Hendricks, senior key account manager at ModuleWorks, says: “This three-way collaboration is an excellent example of how Industry 4.0 encourages heterogenous partnerships for developing innovative new manufacturing solutions. We look forward to continued co-operation and further advances in the technology.”

Marko Stugbäck, product manager at Sandvik Coromant, adds: “ModuleWorks has the experts and resources that enabled us to turn the PrimeTurning method into a software solution for the CAM market. It’s great to see HCL implementing this technology in CAMWorks. These types of collaborative efforts are exactly what the industry needs to ensure continued ingenuity that enhances the productivity and quality of automated manufacturing.”

For further information
www.moduleworks.com

The new QTE series of CNC turning centres from Yamazaki Mazak is the first to feature SmoothEz, the latest generation of Mazatrol CNC. Mazatrol SmoothEz CNC combines three ‘easy’ features: Ez Machining, Ez Operation and Ez Setup.

Ez Machining offers machine users high-speed, high-accuracy machining with thermal compensation control, delivered by Mazak’s Thermal Shield, to maximise accuracy by automatically compensating for temperature changes in the machining area. Ez Operation includes Quick Mazatrol for fast conversational programming via a 15” (380 mm) touch screen and intuitive operating system that can be customised according to operator preference.

By integrating Mazak’s Smooth CAM Ai and Mazatrol Twins, it is possible to replicate a virtual copy of the machine in the office for enhanced set up. Collective management of machine data is synchronised between the factory and office with Smooth Project Manager to manage the data required to execute machining programs – including tool data, work holding, system co-ordination, parameters and 3D workpiece models.

Additionally, Smooth CAM Ai can reduce programming time with Solid Mazatrol to generate a program from a 3D model using AI deep learning to determine the optimal process from past programs.

The QTE Series is equipped with a 5000 rpm built-in spindle motor that is capable of high acceleration and deceleration. Since there is no loss of power through mechanical transmission, the built-in-motor delivers more output during cutting, while vibration is minimised during high-speed operation to ensure enhanced surface finishes and extended tool life.

Two turret selections are available with a 12-position drum turret as standard and an eight-position turret as an option. Each utilise a 25 mm turning tool shank size.

For further information
www.mazakeu.co.uk

The trend toward smaller batch sizes is affecting all machine tool development programmes, including those for multi-spindle automatic lathes. Whereas machines used to produce many millions of parts throughout the year without re-tooling, it is now common for subcontract lathe operators to re-tool their multi-spindle machines every two to three days. Set-up times therefore have a significant impact on unit costs.

Karl-Heinz Schumacher, head of development and design of multi-spindle machines at Index (represented in the UK by Kingsbury), says an optimised set-up concept is therefore essential when looking to the future: “Batch sizes are going to get even smaller. This means we need to devise solutions that accelerate tooling and set-up and – no less important – simplify these processes while maintaining a high-precision result.”

The development teams at Index have included a range of effective solutions on the new MS24-6 multi-spindle automatic lathe, as they did previously in the MS32-6 launched last year. One special feature is the Index quick-clamping system with integrated W-serration on the cross slide. Instead of the previously common dovetail system, each cross slide now features a W-serration to simplify micron-precise alignment of the tool holder. The W-serration eliminates the degree of freedom in X, meaning that operators can simply attach the tool holder, which is already pre-set in the X and Y directions. It is attached using a quick-clamping system developed by Index that fixes the holder in position using a tie rod and a pre-tensioned wedge rod. Just a quick turn with the wrench ensures the firm contact required for use.

“This makes the operator 50% faster than when changing holders the conventional way, and practically eliminates the risk of errors,” says Schumacher.

For further information
https://kingsburyuk.com/

The first fixed-head lathe in Citizen Machinery UK’s Miyano range to feature the company’s patented LFV (low frequency vibration) chip-breaking software in a FANUC control system is the new, 42 mm bar capacity ANX-42SYY. It features 10 CNC axes including a ±35 mm Y axis on both the upper and lower turrets in addition to X- and Z-axis movements, enabling the production of complex components to tight geometrical tolerances.

LFV involves synchronising the rotation of the spindles with high-frequency oscillating motions of the tools in the X and Z axes to break what would normally be stringy swarf into manageable chips that can be disposed of easily. During turning and drilling, swarf is prevented from entangling around the component and tool, which would otherwise risk damage to both, and prove time-consuming to remove. Machine stoppage for swarf clearance is unrequired, even when machining materials such as stainless steel and plastics.

In addition to LFV software, which is programmable via G-codes in the part program, the 15” (380 mm) XGA touch panel FANUC 31i control features a new Citizen HMI and incorporates the company’s multi-axis technology. This configuration allows three-axis simultaneous cycles, double Y-axis cutting and superimposed machining whereby three tools can be in cut at the same time thanks to X-axis movement of the sub spindle. The technology also helps to share operations between the two spindles more evenly, which helps increase production efficiency and throughput.

The 6.2-tonne machine occupies only 2650 x 1630 mm of floor space. Both main and sub spindle have a bar capacity of 42 mm diameter and are powered by 11 kW/6000 rpm built-in motors.

For further information
www.citizenmachinery.co.uk