Andover-based aluminium die-casting company MRT Castings uses robotic systems in its foundry, but until now automation has not featured in the company’s machine shop, apart from a twin-pallet changer on machining centres from the Japanese manufacturer Brother, supplied through sole agent Whitehouse Machine Tools.

This situation is due to change following an order placed by MRT’s managing director Phil Rawnson at the Southern Manufacturing show in February for a Brother Speedio M140X2 mill-turn centre with Feedio robotic component handling system. The Feedio unit supplies raw material automatically to the machine and returns finished components. MRT’s new cell, which will be the first five-axis machining capacity on site, is due to be operational this month.
Rawnson says: “We had been looking to introduce automation into our machine shop for several years, as we see it as the future for our company. At present we operate a day shift with a few hours’ overtime in the early morning and evening. The Brother cell will add to this by allowing us to run lights-out for up to eight hours, depending
on component size and cycle times, as well as unattended during the day. We expect it to have a big impact on our productivity.”
The plug-and-play Feedio automation unit communicates with the machining centre via a Profibus interface. Feedio is supplied with a six-axis ABB robot and the manufacturer’s smart teach pendant incorporating a customised Speedio page.
MRT’s first family of components to be produced on the new automated equipment will be a selection of aluminium bodies for a range of LED light fittings.
Rawnson concludes: “We plan to target a wide range of different components for production in the new mill-turn cell.”
For further information www.wmtcnc.com

The Okuma MCR-S (Super) double-column machining centre, which is particularly suited to the machining of press dies, is being released in the UK via agent NCMT. Importantly, the machine also unites subtractive and additive manufacturing methods, allowing for process-intensive production.

Okuma’s MCR-S possesses a cast-iron double-column structure that is equipped with Okuma’s ‘Thermo-Friendly’ concept. As a result, any unnecessary heating-up can be prevented, while thermal deformations are compensated. When manufacturing press dies, this factor is especially important because the machining process can often take days or even weeks, making it vulnerable to changes in temperature.
Using a swivel image sensor that rotates relative to the indexing angle of the tool means that accurate measurements of cutting-edge position can be provided, improving accuracy even further. This sensor also helps to ensure traceability by recording the captured images.
MCR-S machines possess a heavy-duty cutting capacity, reaching a chip removal rate of 710 cm3/min when face milling. Average continuous feed rates of 20 m/min for the X and Y axes, and 10 m/min for the Z axis, contribute to the machine’s productivity. In addition, the ServoNavi application autonomously maximises table acceleration according to component weight.
For process-intensive manufacturing, the machining centre is equipped with a laser that allows for additive manufacturing via laser metal deposition (LMD). This way, subtractive and additive manufacturing methods are combined in one machine, enabling manufactures to not only produce complex parts, but to repair defective workpieces. The laser can also be used for surface treatments, such as laser hardening.
For further information www.ncmt.co.uk

Chester Machine Tools has been extremely busy during the first quarter of 2019, with approximately 255 machines shipped globally from the company’s Burntwood factory in Staffordshire.

The most recent project was a customised Chester HB110/3 horizontal boring machine for a dockyard in Portsmouth. Engineers from Chester Machine Tools took an expedient one and a half weeks to construct the bespoke machine, which was hand built and automated at Burntwood.
“The horizontal HB110 series borer is testament to the capabilities of Chester Machine Tools and its custom-built machines,” says Anthony Edwards, the company’s sales director. “It is a versatile machine that can be used in multiple manufacturing and industrial environments.
“We specialise in providing bespoke machines to order, tailored to our clients’ specific requirements, and we aim to deliver the highest quality and reliability for each unique business environment,” he continues. “Chester’s skilled engineers assemble the purpose-built machinery, while also providing commissioning, installation and training as part of the total service packages offered with all of our machines. In addition, we can provide post-installation support and planned maintenance for the lifetime of our machine tools.
“The HB110 constructed for the dockyard customer is just one of the large industrial-sized machines in our range; we offer multiple machine solutions for any application.”
For further information www.chestermachinetools.com

Meeting the precision needs of its customers has seen a Huddersfield manufacturer make a number of large investments, including the acquisition of the latest CNC machine technology.

Thomas Brown Engineering, which celebrated its 35th anniversary in 2018, worked with the Engineering Technology Group (ETG) to install a new Hardinge Bridgeport XR1000, which will help it capitalise on three recent contract wins for the aerospace sector.
The company will use the additional power and torque provided by the GTW spindle to machine tough materials, while the Heidenhain TNC 640 control and Nikken 4th-axis rotary table are intended to increase accuracy, flexibility and repeatability.
In recent years, Thomas Brown Engineering has seen its turnover increase and new jobs created; the company’s workforce now stands at 20 people.
“We have always been big fans of Hardinge Bridgeport and the excellent performance the machines deliver, so it was no surprise when we updated our capabilities with the new XR1000,” explains Tom Brown, who founded the business in 1983 after serving an apprenticeship and working at a local firm. “Aerospace is a growing market for us following our AS9100 accreditation, and this helped us secure three important contracts which required more capacity and shorter lead times.”
He continues: “We spoke to ETG about our requirements and came up with the XR1000, specifying it with a Nikken 4th axis rotary table to give us the opportunity to produce more complex components. It is a decision that is already paying off, with some cycle times reduced by as much as 20%. This makes a major difference to our productivity.”
The machine also features a Blum TC50 spindle probe and ZX-Speed IR tool-setting probe.
For further information www.engtechgroup.com

Essex-based MKB Precision Engineering has installed a large XYZ 1100 HD (Heavy Duty) machining centre.

When creating their company, Ken Barnard and his son Matt had just a second-hand manual lathe, a grinding machine and an XYZ ProtoTrak mill. Within a couple of years, business had developed and the company’s first XYZ 710 vertical machining centre arrived, quickly followed by a second. These two machines, with their Siemens Shopmill controls, enabled MKB to fulfil orders that would have not been viable previously, leading to good business growth.
As demand for larger components grew, the pair recognised that a machine was needed with greater capacity, and the larger XYZ 1100 HD was the obvious model of choice.
“While we had our XYZ SMX 5000 ProtoTrak bed mill, part exchanging that for the XYZ 1100 HD was a natural progression, and the addition of tool-changing capacity and fully enclosed guarding allowed us to maximise productivity,” says Ken Barnard. “When we saw the carcass of the XYZ 1100 HD at the MACH exhibition, it gave us the confidence that this larger machine would perform in much the same way. And, with the XYZ 1100 HD having the same Siemens 828D control featuring Shopmill conversational software, it makes it straightforward to transfer work from one machine to another.”
MKB Precision Engineering bought the XYZ 1100 HD specifically for its machining envelope, particularly the large Z axis, which allows the company to easily machine workpieces over 620 mm tall. The large table, at 1100 x 600 mm, can also be utilised to machine smaller parts or, indeed, components in multiple set-up configuration.
For further information www.xyzmachinetools.com