FEATURE ON CNC MILLS & MACHINING CENTRES

Starrag Supplies High-Precision Heckert HEC 800 To Kapp Niles

In 2024, Kapp Niles replaced a 16-year-old jig-boring machine at its Coburg production facility with a high-precision Heckert HEC 800 machining centre from Starrag. For Sascha Forkel, head of prismatic machining, the replacement was akin to a heart transplant: “It’s a key machine in our production operations, without which we would no longer be able to supply.”

Kapp Niles machines prismatic components up to 1 m³ in size, to tolerances as tight as 3 µm. The components, made predominantly from cast iron, are pre-machined before finishing, where accuracy and surface quality are critical.

The ageing jig-boring machine presented an increasing failure risk, with spare parts no longer guaranteed. Kapp Niles therefore shortlisted three potential replacements and subjected each to identical trials using the same complex motor housing, tooling, NC programs and clamping devices.

The company ultimately selected Starrag and its Heckert HEC 800, equipped with a high-precision kit. Mechanical accuracy was a key consideration.

“Various manufacturers achieve similar accuracies through compensation in the control software,” explains Forkel. “This can cause problems. For us, bores must be cylindrical.”

The HEC 800 incorporates water cooling for stands, axis drives and ball screws to ensure thermal stability, while heat sources are isolated from accuracy-critical components. Starrag also further tightened the circular-axis tolerances and reduced B-axis wobble.

A direct-drive spindle was selected, with maximum speed deliberately reduced from 12,000 to 10,000 rpm to increase process reliability. An Erowa LoadMaster automation system with nine pallet stations was also installed, allowing uncritical components to be machined without human intervention.

The old machine was removed in July 2024, with the HEC 800 arriving in August. Following site acceptance and operator training, production began in January 2025.

“Our conclusion: the heart transplant was a complete success,” states Forkel.

More information www.starrag.com

Rainford Precision Secures Alzmetall Partnership in UK

Rainford Precision has announced a new partnership with German machine tool manufacturer Alzmetall, becoming an agent for the company’s drilling and machining centre technologies throughout the UK and Ireland. The agreement combines Alzmetall’s German engineering expertise with Rainford Precision’s technical and application knowledge, providing manufacturers with direct access to high-performance machining solutions designed for precision, productivity and long-term reliability.

At the heart of the new offering is Alzmetall’s GS Series of machining centres. Manufactured in Germany, Rainford says the range is recognised for its build quality, rigidity and accuracy, making it suitable for demanding applications across a variety of industries.

The GS series incorporates an intelligent carriage travel system based on a box-in-box design with a symmetrical structure and monoblock cross slide. This configuration delivers stability, while the Z-axis slide and spindle are mounted directly within the carriage body to help maximise rigidity and machining performance.

Available in five sizes – GS 600, GS 800, GS 1000, GS 1200 and GS 1400 – the range supports component diameters from 600 to 1400 mm. Multiple machine variants are available within each size category, enabling manufacturers to select a solution tailored to their production requirements.

A key feature of the range is the SDK NC swivel/rotary table, which can be specified with either gear-drive or direct-drive torque motor technology. This application-focused approach allows customers to optimise machine performance for both conventional five-axis machining and dynamic operations requiring high positional accuracy.

For larger and more demanding applications, Alzmetall’s patented ASGK gantry concept assigns all three linear axes directly to the gantry structure, creating a rigid platform capable of handling substantial workpieces while maintaining the precision, repeatability and productivity expected from premium German-built machine tools.

More information www.rainfordprecision.com

Higher Precision With Advanced Mill-Turn Machine Technology

Precision engineering specialist ANT Industries has strengthened its advanced manufacturing capability with a six-figure investment in a new Axile G8 mill-turn centre at its facility in Atherstone, Warwickshire.

The machine forms part of the company’s ongoing strategy to expand its role as a trusted supplier of complex components to the aerospace and gas turbine sectors. Combining high-speed machining with advanced multi-axis control, the Axile G8 is being deployed primarily for the manufacture of high-value aero-engine components where precision, repeatability and surface quality are critical.

Managing director Shaun Rowley says early trials have already demonstrated significant performance benefits: “From our initial testing, the machine has exceeded expectations for accuracy, speed and ease of programming. The combination of processing power, axis control and machining speed gives us greater accuracy when producing complex profiles.”

The Axile G8 has also delivered notable improvements in surface finish quality, an important requirement for demanding aerospace applications.

“Parts produced on the machine have an exceptional finish,” says Rowley. “In many cases, the surface appearance is closer to a ground finish than a milled one, which is a reflection of the machine’s rigidity and precision.”

A key feature of the machine is its centred trunnion construction, designed to maximise stability and control during machining operations. The rigid structure enables tighter tolerances and improved consistency when producing complex geometries.

The machine also allows multiple milling and turning operations to be completed in a single set up, eliminating the inaccuracies that can occur when parts are transferred between machines.

“Our main reason for investing was the accuracy gained by removing multiple changeovers,” he adds. “The machine delivers exceptional repeatability, allowing us to produce highly complex components efficiently and consistently.”

More information www.antindustries.com

Integrated machining, automation and digitalisation on show

Heller will demonstrate its expertise in high-precision component machining for the aerospace sector at the Farnborough International Airshow 2026 (20-24 July), where the company will exhibit as part of the Midlands Aerospace Alliance in Hall 1. The event will provide an opportunity for the horizontal machining centre specialist to engage with manufacturers in the industry and highlight technologies and engineering capabilities that support the production of complex aerospace components.

As global aircraft demand continues to drive growth across the sector, manufacturers are increasingly seeking solutions that deliver greater productivity, process reliability and cost efficiency. Heller has established a strong position in this market by combining advanced machine tool technology with extensive application knowledge and digital engineering expertise.

A key area of focus is the machining of challenging aerospace materials, including titanium, Inconel and other heat-resistant superalloys commonly used in structural and engine components. These materials present significant machining challenges, requiring a high degree of process stability and precision to achieve consistent results, while minimising production costs.

At Farnborough, visitors will learn how Heller’s machining platforms are designed to meet these requirements through elevated levels of rigidity, accuracy and dynamic performance. The company’s production systems help manufacturers maintain reliable production while meeting the stringent quality standards demanded throughout the aerospace supply chain.

Alongside its machine tool technology, the supplier will explain its capabilities in digital engineering and process simulation. By creating digital representations of complete machining environments, the company enables customers to validate production strategies, optimise fixtures and toolpaths, identify potential process issues and confidently quote for contracts. The approach helps to reduce development time and improve production planning.

Process optimisation is also part of Heller’s aerospace offering, where the company supports manufacturers with integrated automation solutions.

More information www.heller.biz

Mikron is a driving force behind impeller manufacture

United Machining says its Mikron Mill P U range of simultaneous five-axis machining centres provides manufacturers with an advanced solution for the efficient production of complex open, semi-open and closed impellers.

Impeller machining is a demanding process that requires precise control of complex blade geometries through roughing, semi-finishing and finishing operations. Achieving the required dimensional accuracy and surface finish, particularly on thin-walled and highly contoured blades, depends on the seamless integration of machine tool performance, cutting strategies and toolpath optimisation.

The rigid design of the Mikron Mill P U series, combined with high-torque motors, direct-drive Step Tec spindles, advanced thermal compensation and automated calibration systems, enables manufacturers to machine complex impellers faster and more accurately. During roughing, advanced five-axis strategies optimise tool engagement and maximise material removal rates, while semi-finishing creates a consistent stock allowance for stable finishing operations.

Finishing remains the most demanding stage, requiring uninterrupted toolpaths and precise tool orientation to achieve high-quality blade surfaces. The machine’s simultaneous five-axis capability ensures smooth, continuous movement, reducing vibration, improving surface finish and shortening cycle times.

Torque motors fitted as standard provide exceptional rigidity, stability and vibration damping, while eliminating mechanical wear associated with conventional drive systems. Automated Machine Calibration (AMC) further enhances accuracy by simplifying machine calibration and reducing the potential for human error.

To minimise downtime, Machine Spindle Protection (MSP) instantly detects collisions and safely stops the machining process, helping to prevent spindle damage and preserve machine geometry. High-performance Step Tec spindles deliver the speed, power and reliability required for both aluminium and titanium machining applications.

Together, these technologies enable the Mikron Mill P U series to provide the stability, precision, productivity and process security required for modern impeller manufacturing.

More information www.gfms.com