FEATURE ON CNC MILLS & MACHINING CENTRES

Wele HMC500 launched in UK

The latest addition to the Wele range of machining centres is the HMC500 horizontal spindle model, which offers positioning accuracy of ±0.005 mm in the X, Y and Z axes, and a repeatability of ±0.003 mm over the full working strokes of 640 mm in X, 610 mm in Y and 680 mm in Z. With 60 m/min rapid traverse rates in each axis, positioning times are reduced, contributing to shorter cycle times and higher levels of productivity.

Launched in the UK by 2D CNC Machinery, the 500 mm twin-pallet machine (optional 400 mm pallet size) has a maximum workpiece capacity within a cylinder diameter of 750 x 900 mm high with a full B axis. The B axis has 1600 Nm of torque and a positioning accuracy of 10 arc-secs (with a repeatability of 6 arc-secs). Also featured is a zero-point clamping system via four radial pre-tensioned tapers to ensure alignment. Index times are 1.5 seconds with a pallet interchange time of 7 seconds.
The built-in 22 kW, Big-Plus dual-contact spindle has a speed range between 40 and 15,000 rpm with up to 167 Nm of torque available through a low and high-range transmission. Spindle acceleration and deceleration is 3.3 seconds. In order to minimise any deformation caused through variable cutting forces or thermal effects, the spindle head is mounted between twin box-type gantry columns, while the cast-iron bed is supported via three-point levelling.
There is a 60-tool magazine, providing 3 seconds chip-to-chip time, which is capable of carrying tools up to 80 mm diameter (or 160 mm with adjacent pockets left empty). Maximum tool length is 400 mm. Control is via Fanuc 0i-MF.
For further information www.2dcnc.co.uk

Kafo machine chosen for defence parts

Rotherham-based Newburgh Precision Ltd, a contract manufacturer of project-critical component parts and assemblies, has acquired a new Kafo KMC-4140 double-column CNC machining centre from sole UK agent, TDT Technology. The machine has been purchased to produce high-value components for the defence industry.

“We recently secured a long-term defence contract for large stainless steel components and needed extra capacity,” explains managing director David Greenan. “Initially, we began producing the parts on an existing bed mill, but this machine already had a busy workload and it was apparent we needed a new resource.”
Assessing the various options online, Newburgh Precision shortlisted two machines, including the Kafo KMC-4140, which met the company’s requirements of size, capability, build quality and price.
“As luck would have it, we were aware of a company in France that had both of the machines on our list,” says Greenan. “One of our team paid them a visit and, upon discussion, discovered they had a preference for the Kafo. In my opinion you cannot beat personal recommendation when you are making machine tool investments.
“To be honest, the Kafo is not the most expensive machine in the world, but its build quality – in terms of strength and rigidity – belies its price tag,” he adds. “This is good news for us because the free-issue material for the stainless steel defence part carries a value of £80,000 per workpiece. As a result, high build quality is paramount in ensuring precision and repeatability.”
Newburgh also says the speed of the Kafo machine means the company can process parts around 25% quicker than using its bed mill.
For further information www.tdt-technology.co.uk

Valve producer has preference for Heller

The manufacture of braking systems for rail vehicles is the specialism of Knorr-Bremse Rail Systems UK, which says that its patented EP2002 distributed brake control is recognised as the best in the world and the de-facto standard on all new trains for London Underground as well as metros in Bangkok, Dubai, Manila and throughout China.

Designed at the company’s engineering and manufacturing facility in Melksham to a very high specification, which includes 25 µm dimensional tolerances and a mirror finish of 0.2 CLA in the valve bores, the products comprise eight main prismatic parts. They are machined at a production facility in nearby Knorr-Bremse Corsham from solid aluminium on six Heller twin-pallet HMCs. The latest was installed in July 2017, fitted with a four-pallet pool.
Paul Ranford, improvements manager at Corsham, says: “Knorr-Bremse Rail Systems UK inherited four Hellers when we took over the subcontractor in Corsham that was previously manufacturing the parts for us on this site. We have since considered a couple of other potential suppliers of HMCs, but we saw no reason to change, as Heller’s UK headquarters is only two hours away. They also have a manufacturing operation there, so the technical expertise and service capability available in this country are more in-depth than would otherwise be the case.”
Ranford regards the working relationship with the supplier and the service back-up as first rate, which translates into minimum spindle downtime at the factory and the all-important high levels of manufacturing output that are needed.
For further information www.heller.biz

Clausing MillPWR CNC mill unveiled

600 UK has announced the latest addition to its Clausing range of machine tools, the MillPWR CNC mill. The machine is fitted with an Acu-Rite conversational-based control system from Heidenhain, which is available in four languages: English, French, German and Spanish.

According to 600 UK, the MillPWR mill allows users to create and program complex parts in minutes, manufacture one-offs and small-batch parts, and routinely mill prototype and test components. Scales with a resolution of 1 µm resolution are fitted as standard.
The MillPWR Acu-Rite control uses a 12.1” screen, displaying graphics in either 2D and 3D line, or 3D solid formats. Operators can also upload, edit and run G-code and DXF files, enabling the use and transfer of programs directly to and from the machine. There is 2.5 GB of internal memory and the ability to store and modify up to 99 part programs. For external storage, USB and Ethernet capability are also available as standard.
The MillPWR CNC mill is supplied in three models, with table sizes from 230 x 1245 mm and 254 x 1370 mm. Motors offering power of 2.2 or 3.7 kW are employed, giving spindle speeds of up to 4350 rpm. Spindle tapers of either R8, ISO30 or ISO40 can also be supplied.
For further information www.600uk.com

F1 firm expands five-axis machining

In 2015 Ray Harris set up his own subcontracting company, Driven Precision Engineering, to specialise in F1 manufacturing. He rents space on the shop floor of LW&T Engineering, another contract machining firm in the Farlington district of Portsmouth.

A second-hand, three-axis machining centre was his first purchase, followed by a five-axis model from the same supplier a year later. The latter machine extended the complexity of work that could be taken on by exploiting simultaneous five-axis machining and allowing more efficient manufacture of standard parts by positioning and clamping the two rotary axes.
To add another spindle and increase the size of work that can be undertaken to 850 x 700 x 500 mm, his latest purchase is another five-axis machining centre, this time a Hermle C400 supplied by Geo Kingsbury. Harris describes how he came to buy a machine costing significantly more than a five-axis machining centre of equivalent capacity from the incumbent supplier.
“It was our tooling supplier, Betta-Cut in Southampton, that suggested we look at Hermle, as the sales engineer is an ex-employee of Geo Kingsbury and knew the machines well,” he says. “I searched on the internet and found only positive comments about the machines. Normally you can unearth some negatives about machine tools on discussion forums, but I couldn’t find any about Hermle.
“Then I went to a subcontractor in Gosport, Norjon, whose owner Kevin Fox has operated five-axis Hermles for many years and now has five,” he continues. “He didn’t have a bad word to say about them either, so the C400 more or less sold itself.”
For further information www.geokingsbury.com