An Eastleigh-based precision manufacturer recently turned to Yamazaki Mazak for the installation of new machinery in a challenging four-week timeframe following a project win.

The swift installation and commissioning of a Mazak HQR-200MSY CNC turning centre has enabled GW Martin & Co to expand its machining capacity and fulfil the company’s strong order book.

The machine’s two-turret, two-spindle set-up enables reduced cycle times and, when combined with the long Y-axis stroke, high-accuracy milling. Bar feeders, workpieces unloaders and robots can be integrated if required.

“Having worked with Mazak in the past, we were aware of their reputation for supplying quality turning centres,” says Richard Blake, business development manager at GW Martin. “So, when we required an automation-capable solution at short notice that could machine high-quality components in large volumes, we knew where to turn.

“Our previous experience with a Multiplex W-200Y meant we were fully confident that Mazak could adapt the HQR-200MSY to suit our existing processes,” he continues. “Bearing in mind the time pressures of the project, this was absolutely vital. Yet as we expected, even in such a short timeframe, the installation was completely seamless and risk-free.

“While this all sounds very simple, it really isn’t – Mazak’s adaptability and applications engineering proficiency was already known to us. We really appreciate how they were able to help us react quickly to our project win and, following this success, we have ordered another Multiplex W-200Y.”
Alan Mucklow, managing director UK and Ireland sales and service division at Yamazaki Mazak, adds: “The installation of GW Martin’s HQR-200MSY is a perfect example of how Mazak can assist organisations working in the fast-moving general subcontract sector.”

For further information www.mazakeu.co.uk

Motor racing is in the blood for Jeremy Welch.

His great grandfather built the first six-cylinder engine ever made in the UK (in 1906) and went on to build Brook Marine racing engines with notable success (world champion in 1921). Jeremy’s father founded Denis Welch Motorsport over 40 years ago and the company has had notable success in the UK, Europe, Australia and the Far East.

While building cars it became obvious that older models needed new components, as the originals were no longer available. The company supplies replacement performance parts for classic cars, restores and prepares ex-works cars, and specialises in Jaguar E-type and Austin Healey models.
Three Haas lathes, a UMC-750 five-axis universal machining centre and a VF-4SS super speed vertical machine have been added in the last few years.
“Having our manufacturing in-house has made a massive difference,” says Welch. “We’ve expanded our range considerably and can now control our own processes and quality.

“The training has been tremendous,” he continues. “I’d never written a program, but with Haas’ help I jumped straight on the five-axis machine. We do mainly 3+2 machining, which enables us to use fewer fixtures, and most programming is completed manually at the control using the Haas G254 dynamic work offset function. One of our operators had never used a CNC, but after training with Haas he now writes programs on our Haas ST-25Y lathe using Y axis and live tooling.”

The latest acquisition is a Haas ST40 turning centre, which is currently machining period magnesium wheels and uprights for race Jaguars.
“We bought the machine especially for this job and it’s been fantastic,” concludes Welch.

For further information www.haas.co.uk

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

If a manufacturer plans to carry out rigorous turning of demanding materials, such as titanium and nickel alloys, care has to be taken to select rigid, powerful lathes.

This factor is especially the case if the intended applications require sliding-head turn-milling, as these platforms tend to be less robust than fixed-head lathes. With this in mind, Lanark-based aerospace manufacturer Martin Aerospace, selected a German-built Traub TNL32-9P for its latest investment in sliding-head technology.
Supplied by Kingsbury, the machine started producing aerospace parts from tough alloys 24/5 from the beginning of 2018. It has been so successful at fulfilling an ongoing contract for producing aero engine components from titanium, Inconel and stainless steel that the business had no hesitation in returning to the same source for a fixed-head lathe. Installed in July 2019, the Traub TNX65 produces parts from Inconel and Nimonic for the same customer.
Both lathes have reduced multiple operations to one-hit production, making it much easier to hold the required tolerances, which are generally to within ±0.01 mm, although one pin diameter has to be turned on the sliding-head lathe to ±4 µm. At the same time, process cycles have been shortened, by over 90% in one case on the TNL32-9P and by typically 70% on the TNX65. Such significant savings are partly a result of the ability on both machines to have three tools in cut simultaneously, each having a different feed rate for optimum metal removal.
Neil Lawson, operations director at Martin Aerospace, says: “Both machines are ideal for the efficient production of parts in high volumes from tough materials, and are platforms for continuous process improvements. This has allowed us to secure additional work, as we are able to provide significant savings to our customers.”
For further information www.kingsburyuk.com