FEATURE ON CNC MILLS & MACHINING CENTRES

Ingenieur automates milling to boost productivity

Machining contracts for the civil aviation, defence and space sectors make up about 60% of turnover at Ingenieur Ltd, Chandlers Ford, with oil and gas accounting for much of the remainder. Turned parts production is only 30% of throughput, the rest being prismatic machining on seven VMCs, the latest two of which are German-built Hermle machines. Supplied by sole UK sales agent Kingsbury, they are the subcontractor’s first five-axis models.

To alleviate a bottleneck in production, a refurbished Hermle C 40 U arrived at short notice on loan from Kingsbury’s showroom in Gosport. The machine was subsequently purchased. A new Hermle C 400 arrived soon after, linked to one of the machine manufacturer’s own HS Flex systems for exchanging 24 pallets automatically, allowing long periods of unattended running. The machining centre features an 18,000 rpm spindle, through-spindle coolant, an extended magazine to accommodate 90 tools, Blum tool measurement and breakage control, and a Renishaw touch probe.

Ingenieur’s general manager Chris Barton says: “Before the Hermle machinesarrived we were quoting and winning a lot of new business in a number of sectors. In a short space of time we gained four additional contracts, so extra milling capacity was needed really quickly, which thankfully Kingsbury was able to supply.”

Ingenieur selected the trunnion-type Hermle fives-axis VMCs due to their high-quality build and the proximity of Kingsbury for providing service and aftersales support. In addition, the machines were available with a Heidenhain 640 control to enable programs from the company’s other VMCs, all of which are fitted with the same make of CNC, to run with very little editing.

More information www.kingsburyuk.com

Linear drive to innovation with UX450L

Introduced to the UK in the spring, the new Sodick UX450L high-end machining centre from Sodi-Tech UK has already made a major impact on manufacturers since it landed on the UK shores. As a pioneer in linear drive technology, Sodick created the world’s first independently developed linear drives incorporated into mass-produced machine tools. Over 25 years later, Sodick says its next-generation technology is pushing the limits of what is possible with the arrival of the new UX450L.

Conor Plaskitt, technical sales manager at Sodi-Tech UK, says: “We’re well known for EDM but not so much for high-speed machining. However, the two work together well. For a typical copper or graphite electrode manufacturer, the Sodick UX450L is the perfect machine. If you look at processes where spark erosion isn’t always necessary, the UX450L presents the ideal solution for hard milling where manufacturers want ‘mirror-like’ surface finishes and very tight tolerances.”

He continues: “The machine has a 40,000rpm spindle and, as Sodick is a world leader with its linear motor technology, the ability of the machine kinematics and axis movements to start and stop very quickly with pinpoint precision is exceptional.”

From a specification perspective, the Sodick UX450L has X, Y and Z-axis travel of 450 x 350 x 200mm with a 600 x 400mm work table.

“The machine is perfect for complex components that need very high surface finishes, such as mould tooling,” says Plaskitt. “The UX450L can achieve high-quality surface finishes that eliminate the requirement for time-consuming grinding or secondary polishing. Likewise, the machine can replace jig grinding applications – another skill that is gradually disappearing.”

More information www.sodick.eu

Heavyweight champs of the (tooling) world

Renowned within the industry for its plastic mould tool and pressure die expertise, Midlands-based Superite Tools has invested in a trio of large capacity CNC milling machines to further extend its capacity. The three Hurco machines modify, repair and enhance customers’ tooling.  

General manager Craig Dingle says: “Being one of the few companies in the country that can handle tools weighing up to 15 tonnes means we have very little direct competition, whichmeans we’ve established a sustainable customer base. Our latest investment in the three Hurco milling machines enhances this foundation even further because we now have the ability to load tools up to 2200 x 1700 x 750 mm on the bed at weights up to 8 tonnes.”

This impressive capacity is provided by a large double-column Hurco DCX 22 vertical machining centre that features a 12,000 rpm 18 kW spindle, supplied by a 40-tool automatic tool changer. With rapid traverse rates of 24 m/min and cutting feed rates of up to 7 m/min, it can certainly chew through some metal.

Alongside the twin-column machine are two Hurco VMX 60T three-axis vertical machining centres designed to deliver high-precision, high-productivity capabilities for batch production, one-offs or mould and die work. Offering a machining envelope of 1524 x 660 x 610 mm in X, Y and Z, these machines can accept workpieces up to 2000 kg on the 1676 x 660 mm worktable.

As well as tooling modification and repairs, these machines also provide an increase in the capacity of the precision-machined parts that the company produces as a subcontract service. Although Superite machines a high variety of parts, batch sizes are intentionally low.

More information www.superite.co.uk

SW presents world firsts at AMB 2024

Schwäbische Werkzeugmaschinen (SW) will present two innovations at the AMB 2024 exhibition in Stuttgart on 10-14 September. For the first time, the company will provide insights into the efficient production of large parts for the aerospace industry and giga-castings with the BA space3-22 on stand 10B51 in hall 10. In addition, this specialist in multi-spindle machining centres will present the world’s first machining centre for multi-spindle power skiving, the BA W06-21.

With the introduction of the multi-spindle BA space3-22, SW says it is setting standards in the efficient production of large and complex components. “The BA space3-22 combines precision with short machining times for demanding components, such as those involved in the giga-casting of large components in the field of e-mobility,” explains André Harter, head of marketing and business development at SW. “We have thus further advanced the paradigm shift towards e-mobility and established ourselves as a pioneer in the machining of complex components such as battery housings.”

The BA space3-22 is for the precise machining of large light metal workpieces and offers maximum flexibility thanks to two independent three-axis units in box-in-box design, optionally with five-axis machining. For large parts, both spindles can work simultaneously on a workpiece and change tools independently. At AMB, SW will demonstrate the versatility of the BA space3-22 with an underbody for an automotive supplier and wing ribs for an aircraft body.

With the BA W06-21, SW is presenting another world first at the booth. “The BA W06-21 with power skiving technology reduces production time by up to 50% compared to conventional processes,” explains Patrick Schneider, product manager at SW. “Thanks to multi-spindle machining in a single set-up, we achieve maximum production output with maximum flexibility.”

More informationwww.sw-machines.com/en

Danobat buys Delta Wheel Truing Solutions

Vertical turning lathe (VTL) manufacturer Danobat is strengthening its position in the North American rail market with the acquisition of US-based company Delta Wheel Truing Solutions. Signing the agreement at Delta’s headquarters in Escanaba, Michigan, Danobat continues to make its way in the United States. Danobat entered the US market in 1982. The company has a technical centre in Chicago focused on the development of solutions for processes such as hard turning.

“This acquisition is an important boost that will position us as one of the benchmark players in the North American rail sector, bringing competition for in-situ wheel profiling maintenance that has been lacking in North America,” says Oskar Uria, director of the Railway Business Unit at Danobat. “Delta’s expertise and know-how will be a strategic support for Danobat to grow in such a demanding market.”

The main objective of this approach is to get closer to the US market, offering products tailored to the specific needs of customers in the North American railway sector. In addition, the Escanaba plant will provide direct services, ensuring a close and agile service to customers. 

Delta has a team of people with extensive experience in the design and manufacture of rail wheel re-profiling equipment. In addition, it holds several patents on different systems, offering unique solutions to the market. The manufacturing capacity in the US, its products and customer base are key elements for future joint development with Danobat.

Danobat has recently inaugurated a new 130,000 sq ft plant with increased manufacturing capacity at its Elgoibar manufacturing complex in northern Spain. The acquisition of Delta adds to its strategic investments for the coming years.

More information www.danobatgroup.com