FEATURE ON CNC MILLS & MACHINING CENTRES

Soraluce launches high-rail gantry machines

Soraluce, a manufacturer of milling, boring, multi-tasking and automated solutions, is launching its Dynamic Line, featuring the company’s new high-rail gantry machines. The Dynamic Line comprises three machine models tailored to applications in sectors such as aerospace, mould and die, and mechanical engineering, with solutions designed for specific materials like composites, light alloys and steel. The machines are available in the UK from TW Ward CNC Machinery (Ward CNC).

Dynamic Line machines can feature either five-axis contouring fork-type or high-torque milling heads. This versatility ensures the handling of intricate and complex shapes. The machines also come with a splash guarding system to uphold cleanliness and safety standards. Moreover, diverse dust extraction systems, both within the enclosure and integrated into the heads, facilitate the removal of dust and debris generated during machining.

A key feature of the high-rail gantry machines is axis speeds up to 60,000 mm/min and acceleration up to 4 m/s². The five-axis contouring heads offers speeds up to 30,000 rpm.

From a precision perspective, thermal stability ensures that performance remains consistent even in the face of fluctuating temperatures and rigorous machining tasks. Highly calibrated kinematics further support accuracy.

Heavy-duty mechanical heads deliver power up to 73 kW for challenging cutting tasks. Moreover, Soraluce’s new offer delivers a diverse range of mechanical five-axis contouring heads with torque up to 2000 Nm.

Integrated intelligent damping solutions such as DAS+ and DWS, complemented by a full cast-iron structure, augment stability and performance. These features work in tandem to minimise vibration under demanding cutting conditions.

Soraluce’s global business development director Oier Elguezabal says: “These machines embody our commitment to innovation and excellence, empowering manufacturers to achieve unparalleled levels of productivity and quality in their operations.”

For further information www.wardcnc.com

Subcontractor takes up five-axis machining

Based in County Cork, Maas Precision Engineering performs its CNC milling on seven Hurco vertical machining centres. The first arrived more than 20 years ago and is still running today. Mass Precision caters for all quantities, with the company manufacturing anything from one-offs and small batches up to 20,000 or more.

Managing director Tadhg Hurley says: “We owe our business success to Hurco and are confident in the machines. I know we can turn parts around quickly, making prototypes in one day or a maximum of two days. Every person here can program every machine. Whether it be a 20-year-old machine or a new five-axis model, we usually program directly at the machines and can process orders quickly because we know they’re going to be right.”

The machines play their part, but Maas Precision sets out to make the right investment at the right time. In 2018 the company purchased its first five-axis VMC, a Hurco VMX42SRTi with swivelling B axis and rotary C axis set in the table. The main benefit was the ability to complete more operations in a single set-up.

The transition to five-axis machining was clearly a success as a second five-axis model is now in place: a Hurco VMX30Ui of more compact design with a swivelling trunnion carrying a rotary table. Mass Precision can easily transfer programs between the Hurco machines, new and old, to balance capacity utilisation. The company must respond quickly to changing customer demands, so being able to swap production runs between machines helps to build confidence in attaining challenging targets.

For further information www.hurco.co.uk

Autonomous machine optimisation software

Productive Machines, a provider of autonomous machine tool optimisation technology, is making its core technology available in a fully automated software-as-a-service (SaaS) offering. The company says that its SenseNC Finesse software is the world’s first to provide automated optimisation of all milling operations, enabling manufacturers to set up each machine tool and run production without chatter at every cutter location across the tool path.

The software uses an artificial intelligence (AI) model to optimise machine processes and is deployed at more than 10 major manufacturers already, including Renault and MASA Aerospace. By making it available as an automated SaaS product, Productive Machines aims to help many more manufacturers eliminate trial and error iterations on machine tools, reduce waste, and deliver better and faster products.

According to the company, machines configured with the technology not only demonstrate the ability to produce parts in half the original time, but also to improve surface quality significantly and reduce waste by up to 25%. In addition, users report a substantial decrease in tooling costs, up to 20%, on optimised machines.

SenseNC Finesse is now available to manufacturers using Siemens NX CAM software via a software plug-in, enabling them to improve the performance of existing machines within their chosen CAM environment. Productive Machines will launch a plug-in for Mastercam users this summer and make its software available to users of CAM software from other vendors in the coming months. 

Dr Erdem Ozturk, CEO at Productive Machines, says: “Since the beginning of our journey, manufacturers have told us they needed an optimisation solution that doesn’t require extensive experience to use. We’ve poured more than 100 years of our cumulative machining dynamics and software engineering expertise into creating our autonomous, easy-to-use solution for users of all levels.”

For further information www.productivemachines.co.uk

Bryken trebles automated milling capacity

A long-time user of two automated machining centres that exchange parts fixtured on pallets, in 2022 subcontractor Bryken installed a Hermle C12 machining cell with an integrated RS05 robot for loading billets directly into the working area and unloading finished components. It was supplied by Kingsbury, the sole sales and service agent in the UK for the German machine manufacturer.

The installation was followed one year later by a second cell, this time with drawer rather than tray storage. A similar, even more advanced system with gripper exchange and vice jaw change system arrived in early 2024, allowing multiple different parts to run without operator intervention overnight and at weekends.

Bryken purchased the first Hermle cell after an oil and gas OEM placed an order for 600 new types of manifold, bringing the total number of different parts produced for this customer alone to nearly 1400. Almost all manifolds are made of 316 stainless steel.

The company’s director Phillip Taylor explains: “We don’t have any allegiances to machine tool suppliers, always choosing the most appropriate, high-quality kit for the intended purpose. We opted for an automated cell from Hermle as it was the only solution that was a true billet-handling, five-axis machining cell with a fully integrated robot. The other systems offered either had bolt-on component handling or were pallet-exchange configurations.”

At Bryken’s Knowsley factory, the Hermle cells work 24/7 and delivers an OEE above 90%. Taylor says that the machines hardly ever stop. The first two cells produce around 2000 parts per month. One machines about two-thirds of these components spread across 15 different part numbers, while the second has a more diverse workload involving smaller batch sizes.For further information www.kingsburyuk.com

A high-end HMC inside a small footprint

To accommodate the diverse needs of the marketplace, Starrag Heckert has introduced its new H Compact series of horizontal machining centres (HMCs). The benefits of HMCs can sometimes be overshadowed by the sizeable footprint of the machines in comparison to their vertical counterparts. However, with its H Compact Series, Starrag Heckert says it is delivering the benefits of a horizontal with a compact footprint that will appeal to manufacturers.

Looking at the merits of the new machines, Lee Scott from Starrag says: “These horizontal models feature a trunnion table with five-axis capability. We can also incorporate a high-speed table for turning, a configuration that gives us the ‘T’ range. In its basic guise, it’s a twin-pallet HMC with a monobloc mineral cast base that is very vibration-absorbent and stiff.”

The machine column has positive-leveraged ratios that are credit to maximum guideway distances, while weight compensation improves the performance, accuracy and efficiency of the ballscrew-driven Y axis.

Alluding to the pallet system on the new series, Scott says: “It’s a twin-pallet machine where the ground pallet surfaces ensure perfect interfaces for the fixtures, whether it be on a trunnion or a standard B axis. Outside of the machine, we have the set-up station. Thus, while the first pallet is working inside the machining area, the second pallet is either loaded by a robot, an FMS or an operator.”

Taking a closer look at the operator interface on the new H Compact series, the machine incorporates the latest FANUC or Siemens control.

“Operators love our system, it has a touchscreen and multi-screen facility that offers the perfect solution for engineers who want to get the maximum amount of data from the machines,” concludes Scott.

For further information www.starrag.com