Yamazaki Mazak has helped the McLaren Formula One team by supplying and commissioning a new fully-simultaneous five-axis machining centre in just four weeks. The new machine, an Integrex i-100S multi-tasking machining centre is now fully operational at McLaren’s Technology Centre in Surrey. McLaren Racing’s partnership with Mazak, which now stands at in excess of 20 years, takes the total number of Mazak machines currently in use by the team, to 28.

The i-100S benefits from a compact, ergonomic design complete with a large machining envelope. McLaren Racing’s new machine is capable of machining both round and square workpieces up to 500 mm diameter and 854 mm in length, in just one set-up.

Malcolm Jones, manager – machining and fabrication at McLaren Racing, says: “As part of our longer-term investment strategy in manufacturing technologies, we plan for regular machine upgrades to ensure we operate with the fastest, most efficient technology available.”

He adds: “The team at Mazak was able to source a machine and arrange for it to be shipped, installed and commissioned in just four weeks. Not only does it complement our existing machine portfolio, but it underpins our need for more flexible and capable machines. What’s more, features such as the SmoothX CNC and the second spindle will enable us produce components to a higher degree of accuracy – and faster – than our older generation machines.

“The i-100S is the next step forward in our wider plans to refresh our machine shop and invest in the latest simultaneous five-axis machine-tool technology,” he concludes. “We value our close working relationship with Mazak, who help us to make parts faster and more accurately.”

For further information
www.mazakeu.co.uk

Supplying predominantly to the aerospace industry, the Bowmill Group has invested in three machine tools from Matsuura in the past three years.

The company’s journey with Matsuura started in 2019 after securing a prime contract that required a high accuracy yet flexible machine. As part of its research, Bowmill reviewed the MX-330 PC10 from Matsuura. The MX-330 PC10 offers full five-axis capability and probing, which is critical for the company’s required positional tolerances (3-4 µm). Notably, the MX-330 PC10 also has 10 pallets, allowing Bowmill to run several component variations through the same machine and utilising unmanned/lights out operations. Having seen the machine in real-time operation, and after rigorous evaluation, the company chose to invest in this machine for its main site in Poole.

After six months of running the machine, improving cycle-times and implementing flexible manufacturing sequencing, Bowmill decided to purchase a second Matsuura MX-330 PC10 (for its Tewkesbury site) in March 2020. The MX-330 PC10 features 10 pallets and 90 tools.

Some months later, the company needed a larger five-axis machine (500 mm cube) for Tewkesbury and, due to increasing customer demand, once again looked to Matsuura. Following the success of the first two MX-330 PC10, Bowmill decided to purchase a Matsuura MX-520.

MD Nick Epps says: “Despite the global situation, investing in the MX-330 PC10 and MX-520 machines has been key to the future success of our business. We’ve already seen significant improvement to cycle times and OEE data on numerous components, and this has been equally supported by the service and technical support from the Matsuura team, which has been exceptional.”

For further information
www.matsuura.co.uk

Now in its 17th year of business, Hi-Spec Precision Engineering has evolved from a small start-up business to an established subcontract manufacturer that has fully embraced the latest CNC technology and, more recently, automation technology to drive growth and productivity. A case in point is a new 10-pallet Kitamura Mycenter HX250iG horizontal machining centre from Dugard.

As well as its subcontract business, the company is also renowned in the music industry, manufacturing custom precision-crafted electric guitars. Indeed, the company claims to be the only UK manufacturer and sales outlet for precision guitar components such as bridges, control plates, pick-up screws, neck ferrules, neck screws, pick-up surrounds and more. These components are now available for machining on the Kitamura Mycenter.

Managing director Darren Grainger says: “Our milling work has increased a lot over the past year and cycle times are getting longer with more complex components. This means that some jobs can occupy a machine for up to two weeks at a time, so we needed to look at some way of getting higher production rates and more unmanned hours. Horizontal machining centres are known as production machines and seemed like the obvious choice. The 10-pallet pool is the icing on the cake.”

He adds: “We have one order for 300 parts that is about to arrive and each part requires two operations of more than 30 minutes each. This order will tie up one of our existing machines for four weeks doing the first operation and another four weeks completing the second operation. On the Kitamura machine, we will be able to reduce this cycle time from eight weeks to less than two.”

For further information
www.dugard.com

To meet the criteria of ever-expanding customer demands, Chiron has launched its latest machining centre, the five-axis DZ22W. Based upon the proven platform of the existing 16 series, the Chiron DZ22W is available in the UK from the Engineering Technology Group (ETG).

Thanks to its moving gantry design, a rigid machine bed and active component cooling, the DZ22W five-axis machining centre is said to achieve a high level of precision, even for large components. Fast cycle times are supported by high axis acceleration, short changeover times and rapid traverse speeds. The integrated workpiece changing device, which enables blanks and finished parts to be loaded and unloaded during machine operation, further increases productivity.

From a specification standpoint, the DZ22W five-axis has a twin-spindle configuration that can simultaneously work at speed in the 620 x 650 x 600 mm work envelope.

Customers are able to load a maximum component size of 599 mm diameter with a maximum height of 340 mm and a workpiece load of up to 600 kg. Further capabilities include a 61 kW spindle motor that can reach speeds of up to 20,000 rpm. Axis acceleration rates are 10, 10 and 17 m/s2 across the X, Y and Z axes, with a rapid feed rate of 75 m/min. Chip-to-chip time is 3.1 seconds.

The two spindles are available with a choice of HSK-A63, HSK-A100 or HSK-T63 connection, with each spindle having an individual tool carousel of 77 tools.
As with all Chiron models, the DZ22W five-axis machining centre is available in different configurations with customers having the facility to choose between a ball-screw drive and a linear drive.

For further information
www.engtechgroup.com

With fast material removal capabilities and high-rigidity characteristics, GF Machining Solutions says that its Mikron MILL P 500U simultaneous five-axis machining centres deliver accuracy and cutting performance when machining high-precision, complex components made from difficult-to-machine materials. Notably, the thermal stability characteristics of the machines ensures reliable precision over long runs, aided by the integration and availability of smart technology modules.

As well as featuring 1.7 g acceleration/deceleration rates and 45 m/min rapids, the machines are equipped with 36 kW Step-Tec spindles (20,000 rpm) and rotary tilting tables that can accommodate workpieces up to 707 mm in diameter and up to 600 kg in weight. The rotary tilting table (+91/-121° and n x 360°) is available with several options, including T-slot and pallet tables accommodating a payload of 200, 400 or 600 kg.

Incremental, direct-angle measuring systems on the tilting and rotating axes guarantee high positional and repeatable accuracies. Both axes are driven via water-cooled torque motors: one for T-slot tables, and two for pallet tables on the A axis and one on the C axis. For heavy-duty machining, it is possible to clamp the rotary and tilting axes and, for improved machining stability, the titling axis features clamping on both side supports.

As well as the 20,000 rpm Step-Tec HPC190 spindle (with HSK-A63 interface), customers can select Step-Tec’s 36,000 rpm HVC150 motor spindle with HSK-E50 interface. This spindle solution is suitable for mould makers using small cutting tools in conjunction with the aforementioned 1.7 g acceleration to achieve best-in-class surface finishes.

For further information
www.gfms.com