FEATURE ON CNC MILLS & MACHINING CENTRES

XYZ machines elevate stairlift specialist

XYZ Machine Tools is helping Handicare to maintain the accuracy, rigidity and quality of its stairlifts by machining the mating surfaces of its tubular components using an XYZ RMX 3500 bed mill for straight sections and an XYZ RMX 4000 bed mill for curved sections.

Among Handicare’s UK manufacturing facilities is its Kingswinford, Birmingham plant, where the company designs and manufactures straight and curved stairlifts, producing more than 50 every day. The key element of each stairlift is a pair of tubular runners with welded gear racks. These support the seat and, with its pinion drive and rollers, allow it to transport the user smoothly and safely between floors.

Nabil Mohamed, production engineer at Handicare, says: “For straight stairlift sections, the tubes and gear racks are welded together by  a robot and cut to length. We leave an excess of 0.5 mm which we machine off using the XYZ RMX 3500. This process ensures that the gear profile on the rack is perfect when we join the tubes.”

The XYZ RMX 3500 is dedicated to straight sections and has a set of fixtures on the bed, each designed to lock into the gear profiles and position the tube in the exact position required to mill across the end and generate an accurate gear profile and tube length. The open design of the bed mill makes it possible to work with long tube sections that overhang the bed.

For curved profile stairlifts, the process is similar with tube sections machined on the XYZ RMX 4000. This machine has a larger bed of 1474 x 355 mm and fixtures loaded to suit the end-machining of curved sections.

For further information www.xyzmachinetools.com

Deal signed for largest UK robots

Aerospace automation specialist Loop Technology has signed a deal with FANUC UK for
seven new robots – including the largest industrial robot ever ordered in the UK, the FANUC
M-2000iA/1700L. Three FANUC M-2000iA/1700L six-axis robots will be delivered to the
University of Sheffield Advanced Manufacturing Research Centre (AMRC) for its new
innovation facility in South Yorkshire.
Part of Project Compass (Composites at Speed and Scale), the Loop/AMRC deal also
encompasses two further FANUC M-2000iA robots: a 1200L and a 900L model. As part of a
separate project, another 1700L model, along with an additional 900L unit, have been
ordered by Loop Technology to form part of a high-rate composite preforming cell for a
North American aerospace client.
For further information www.fanuc.eu

Injection mould maker automates machining

Based in Budapest, Euroform provides an injection mould-making service from design to
production. The firm currently uses eight machining centres from DMG Mori for tool
production, including DMU monoBLOCKs, an HSC 75 linear and, most recently, a DMU 100 P
duoBLOCK. The latter features a PH Cell 2000 automation system for pallet handling to allow
unattended production at night and during the weekends.
The five-axis simultaneous machining of workpieces up to 1100 mm in diameter by 1600
mm long and weighing 2200 kg has already taken place on a DMU 100 P duoBLOCK.
Euroform’s experience with the machining centre was consistently good, leading to the
purchase in 2022 of a latest-generation model with a 1000 × 1250 × 1000 mm working
envelope.
When Euroform ordered the new DMU 100 P duoBLOCK, DMG Mori already had a large
pallet handling system in development, based on the smaller PH Cell 300. The bigger
capacity automation system handles pallets measuring up to 1100 mm in diameter, so is
able to deploy Euroform’s 1000 × 800 mm pallets. The PH Cell 2000 has 12 pallet positions
on two levels and can accept workpieces up to 1350 mm tall.
As Euroform almost exclusively manufactures one-offs, pallet handling such as the PH Cell
2000 is the optimal solution. Operators set up jobs offline on several pallets using a zero-

point clamping system while machining is in progress on another mould, so production
downtime is minimal, even at night.
Another focus area that supports business development at Euroform is digitalisation. The
mould maker is an enthusiastic adopter of the digital ‘my DMG MORI’ app when it comes to
online service requests.
For further information www.dmgmori.com

BMA opts for Uniport 6000 machining centres

For over 170 years, BMA AG has been a well-known developer and manufacturer of machinery to perform all of the core processes involved in sugar production. In addition to its headquarters in Braunschweig, Germany, BMA has subsidiaries in China, Tunisia and the USA.

“As well as manufacturing our own products, such as centrifuges, we make our comprehensive fleet of machinery available to other companies on a contract manufacturing basis,” explains Jens Dohnalek, the production manager for mechanical machining, mechanical engineering, drum manufacturing and electrical and control cabinet construction at BMA.

The CNC machines from Unisign are also located in his department. BMA purchased its first Unisign machines in 1993, a Uniport5 and a Univers6. Two years later, the company took delivery of its first Uniport6 machine, which just like the Univers has been in operation ever since. In 2018, BMA expanded its fleet of machinery once more with the purchase of two Uniport6000 machines.

BMA machines large quantities of various components made of steel, stainless steel (or duplex stainless steel) and cast materials on its Uniport6000 machines.

“The workpieces that we produce include items such as centrifuge components, housings, scaffolding trestles, tube plates, support plates and tubular shafts, and these machines are also able to accommodate larger components,” says Dohnalek. “That’s very important, as it enables us to machine welded assemblies complete. That wasn’t the case before. We had to do the mechanical machining first and the welding afterwards, which was a big disadvantage.”

As a final point of note, BMA made a conscious decision to purchase Uniport6000 machines that offer pendulum machining, so the company can operate using parallel set-ups.

For further information www.unisign.com

Dugard machine is an ace in the hole

Sussex-based Sink Golf, a manufacturer golf putters, has invested in a Dugard 760 machining centre to produce its bespoke products.

Discussing how the Littlehampton business started, company founder Olly Longlands says: “Four years ago I was living in New Zealand and got into CNC manufacturing. I loved it so much that when I returned home to the UK, I bought a 2008 Dugard machine at auction – and I didn’t even know how to turn it on. I called Dugard and they were absolutely unbelievable.With their help and learning from YouTube videos, I managed to get my business up and running.”

Explaining the arrival of the latest Dugard 760 machining centre, Longlands adds: “When I decided to start running the business full-time it just went from strength to strength. I got so busy that I couldn’t keep up with orders using just one machine, so I bought a new one: it wasn’t going to be anything else other than Dugard.”

The company is machining two types of material, 303 stainless steel and mild steel. Now that Sink Golf has two machines, it is possible to perform the first operation on the new machine and undertake facing on the older machine.

“Some clubs have around four hours of machining time, although we also just produced a Damascus club [a process where multiple metals are joined in layers under extreme heat] that took more than 32 hours,” explains Longlands.“Although processing time varies, the rigidity of the new machine enables us to run the tools faster and harder while improving our surface finishes and tool life. This makes us 40% more productive and secondary manual finishing times are reduced.”

For further information www.dugard.com