FEATURE ON CNC MILLS & MACHINING CENTRES

Starrag meets Metalex’s big machining plans

In a significant investment for the future, Metalex Manufacturing located in Cincinnati, Ohio, has selected Starrag to supply a large-capacity, multi-axis Droop+Rein portal-type machining centre for its newly created Center for Advanced Large Manufacturing.

The machine – the largest ever installed by the contract manufacturer – will provide it with flexible production capacity to meet all foreseeable demands in terms of producing precision milled and turned workpieces in a single set-up. Indeed, the six-axis Droop+Rein T series machine – with its machining envelope of up to 19 m table length, 9.5 m between the columns and 7 m under the spindle – will also help attract new work.
Established in 1971, Metalex specialises in producing complex workpieces for a range of customers in the aerospace, energy, marine and consumer goods industries.
Metalex’s desire to source a machine that would not only satisfy current production needs but also meet all projected demands in the years ahead saw it make contact with a number of machine builders, including Starrag, which in the past has supplied it with a number of machines (a Dörries vertical turning lathe and two Starrag STC horizontal five-axis machining centres).
To help meet application demands at Metalex, Starrag added the two rotary tables and turning tool holders for in-cycle turning operations, and expanded the horizontal and vertical clearances of the Droop+Rein T series machine. Also included was Balluff tool identification, Renishaw probing, Blum laser tool measuring, video monitoring of the work area using four cameras, ARTIS tool and process monitoring, and Brankamp collision monitoring – all integrated via the machine’s Siemens 840 D SL CNC.
The machine is due for delivery in 2020 and production is scheduled to commence in 2021.
For further information www.starrag.com

High-speed five-axis machining cell

At the Gosport factory of Norjon Precision Engineering, a high-speed DA300 vertical machining centre from Makino, the first of its type in the UK, has been supplied as a turnkey package by sole agent NCMT complete with an Erowa storage and handling system for 24 pallets.

It is the subcontractor’s ninth trunnion-type, five-axis machine and is intended primarily for the milling and drilling of aluminium components, but is equally capable of machining stainless steel for long periods.
Kevin Fox, Norjon’s managing director says: “Makino has a reputation for being at the top end of machine tool suppliers in terms of accuracy and reliability, and this particular model is very fast, with 60 m/min rapids and a 20,000 rpm spindle.
Fox adds that the DA300 is built with automation in mind as it is prepared with pneumatic ports in the table, so interfacing the Erowa Robot Compact 80 was seamless.
At present, a family of aluminium prismatic components is being produced in the Makino/Erowa cell.
“We initially set the job up on a Friday evening and inspected the first-off component,” says Fox. “The cell ran continuously over the weekend and the following Monday we measured the first component produced that morning. All of the dimensions were exactly the same, so the accuracy we are achieving in the cell is excellent.”
The Makino DA300 is capable of the fully interpolative five-axis production of complex components. Equipped with integral, direct-drive motors for the swivelling +30° to -120° A-axis trunnion – and for C-axis rotation of the 340 x 300 mm table – the machine deploys a 20,000 rpm, 22 kW, HSK-A63 spindle capable of milling, drilling and tapping.
For further information www.ncmt.co.uk

CNC mill helps control tool-room work

Aylesbury-based motorsport specialist Goodfabs has invested in an XYZ SMX SLV turret mill to help it produce fabrication jigs.

“Because the exhaust systems we produce are bespoke, we either need the car here to fit the exhaust, which is impractical, or need a jig made to replicate the actual mounting points on the car,” says Paul Watson, process manager. “Prior to getting the XYZ SMX SLV we could only machine the smaller parts of jigs, with the rest being outsourced. And, while our subcontractor produced the quality and accuracy required, we suffered some loss of control. With lead times being short, control of production is vital to us.”
The XYZ SMX SLV is the largest turret mill available from XYZ Machine Tools (larger bed mills are available), with a table measuring 1473 x 305 mm that is capable of carrying components weighing up to 580 kg. This capacity is enhanced by axis travels of 1000 x 410 x 400 mm (X, Y, Z). The head can be tilted front to back by +45° to -45° and from left to right by +90° to -90°, with full 360° rotation of the turret possible. Customers have the option of a three-axis DRO (4th axis optional) or, can opt for the ProtoTrak control in either its two- or three-axis configuration. The latter being the choice
for Goodfabs.
“While we already have three- and five-axis machining capability to produce fittings for our exhaust systems, the addition of the XYZ turret mill has introduced an extra dimension to our machining capability,” says Watson.
For further information www.xyzmachinetools.com

Growth drives need for five-axis machining

Investment Casting Systems, which provides a mix of toolmaking and injection moulding services to customers, has seen turnover increase by 51% over the past three years, with forecast growth of 40% to year ending 2019.

This growth, combined with planned future expansion that will double existing floor space, has created a need for even greater manufacturing efficiency. As part of this efficiency drive, the company has purchased its first five-axis machining centre, a UMC-5X from XYZ Machine Tools.
“We started investigating the purchase of a five-axis machining centre about 18 months ago,” says Investment Casting Systems’ technical director James Head. “Initially we were looking at machines with up to 2 m table capacity, but our customer profile changed, which meant we didn’t need such large capacity. This opened the door to the XYZ UMC-5X with its 600 mm diameter trunnion rotary table and 600 mm travels in the X and Y axes.”
The move to simultaneous five-axis machining immediately brought the benefit that Investment Casting Systems was seeking: increased efficiency. The very first job that went on the XYZ UMC-5X was a complex bolster for an injection mould tool that required machining on all six faces. Using existing three-axis machines would have required six set-ups, but this was reduced to two on the XYZ UMC-5X. The result was a saving of 60% in manufacturing time, the elimination of any potential inconsistencies from multiple set-ups and, by making use of a fixture plate, all faces were machined from the same datum point.
“This first experience proved we had made the right decision in adopting five-axis machining to gain efficiency in manufacturing,” says Head. “We have seen similar time savings as we have progressed.”
For further information www.xyzmachinetools.com

Latest innovations from Correa

Nicolás Correa recently participated in the latest edition of the BIEMH exhibition in Spain, showing its Correa Fox model with UAD milling head and a Norma model with rotary table.

During the event, Nicolás Correa took part in the 13th National Awards for Innovation in Digital and Advanced Manufacturing Technologies, entering the category of ‘Machine Tool, components, accessories and tools innovation’ with its UDX milling head.
The UDX is a mechanical transmission milling head with rotation every 0.02° thanks to the double Hirth coupling system (patented worldwide). UDX heads are able to perform 10,000 rpm, and were featured at the show on the Fox 50 model.
Consisting of two 45° bodies, the UDX is designed and built to withstand heavy-duty cutting conditions, as well as semi-finishing and finishing work with precision and speed, says the company. The Fox 50 also includes a 60-station automatic tool changer and a Heidenhain TNC 640 control. Furthermore, Correa says that its total symmetrical design improves the geometry of the machine, which remains more stable when faced with temperature changes.
The Correa Norma is a flexible machine suitable for roughing and finishing operations. The model exhibited at BIEMH was a Norma 25 with integrated rotary table. Also presented was the Correa Delfos 4.0 system, which allows monitoring based on the cloud, automatically recording and analysing machine data to improve efficiency and the production process.
According to AFM Advanced Manufacturing Technology, the machine tool sector has recently achieved a record annual turnover in Spain, at €1690m.
For further information www.nicolascorrea.com