A five-axis CNC machine has been introduced by DMG Mori UK for the laser ablation of geometrically defined textures into the surface of mould tools. According to the company, the machining process is more environmentally friendly than conventional etching and offers greater freedom of design and a high level of repeatability. The new Lasertec 75 Shape is also capable of creating filigree cavities without the need to manufacture electrodes.

A footprint of just 8 sq m is matched with an ergonomic design and a door opening of 1310 mm to ensure convenient access to the machining area. Workpieces of diameter up to 840 mm and height to 520 mm can be accommodated. Parts can weigh up to 600 kg, or 1000 kg with the optional tandem drive of the tilting mechanism supporting the rotary table.
Central to machine operation are a 100 W pulsed fibre laser and 3D processing optics with F-theta scanning lens. The laser is responsible for layer-by-layer removal of material and, in combination with the NC swivelling rotary table, offers contour-parallel laser shaping for fast, trouble-free laser texturing, even in the 3D freeform areas of a mould, says DMG Mori.
Rapid traverse speeds of 40 m/min help facilitate fast cycle times, while ballscrews in the linear axes and cooling measures promote a high degree of accuracy. Travels are 750 x 650 x 560 mm in the X, Y and Z axes.
Control is by a Siemens 840D SolutionLine, which can combine with DMG Mori’s application-specific LaserSoft software and proprietary CELOS graphical user interface.
For further information www.dmgmori.com

Emmegi (UK) has become a machinery partner to Wolverhampton-based Sherwood Aluminium, with the supply of a four-axis CNC machining centre from Tekna.
Sherwood wanted a flexible machine with a larger capacity than its existing Emmegi Comet T6HP machining centre, and needed it to be compatible with a Renishaw probe. After a comprehensive audit of Sherwood’s needs both in the immediate and longer term, Emmegi recommended the Tekna 944, which can accommodate the Renishaw probe, and has a number of other significant benefits.

The 944 is a four-axis machining centre with a mobile gantry and an 8 kW high-torque, electro spindle suitable for the heavy-duty machining of large sections of aluminium and steel. This electro spindle moves along the A axis, allowing machining through a full 180° around the section. The machine can travel up to 7000 mm in the X axis and meets Sherwood’s specific requirement of a wide workable section, with travel in the Y axis extending to a maximum of 1,070 mm. A clamp unit ensures the correct positioning of the sections, even at this extended width.
“Partnering with Emmegi on this machine has given us the best of both worlds,” states operations manager Geoff Woodfield. “We have been able to source the Tekna 944 machine from them with the ideal specification for our needs, and have the benefit of dealing direct with a dedicated, UK-based supplier with full technical and service back up.”
For further information www.emmegi.com

In 1992, Dublin-based Pressco Precision Engineering purchased its first Haas machine, a VF-0 vertical machining centre, followed by a VF-1 two years later. Both machines are still a regular part of the production process and continue to hold tolerance.

Today, Pressco is a global company supplying to some of the biggest life-science companies in the world. Around 40% of work is in the healthcare sector, with much going to mainland Europe and the USA. Aerospace makes up 25%, reaching as far as China and South America. Central to this growth is the company’s relationship with Haas, with the business currently operating 23 Haas machines. In 2015 Pressco invested in a VF-5SS Super Speed vertical machining centre, followed by a UMC-750SS Super Speed five-axis machining centre in February 2017.
“Multi-axis is the future,” says the company’s Stephen Hayes. “We’ve moved up the food chain of customers and are now considered tier 1 by our major clients. Using Haas machines has cut down our handling times and reduced costs, allowing us to be more competitive when quoting.
“The 15,000 rpm UMC-750SS has halved our cycle times,” he adds. “Its full simultaneous five-axis motion is perfect for cutting complex components for our healthcare customers. Moreover, the ability to cut five faces in a single set-up means we load once and the part is finished.
It cuts the labour right down.”
First attracted by the competitive price of Haas, Hayes says it is the high level of service that brings them back each time: “The machines are very reliable, but if there is an issue, the engineer and parts arrive next day.”
For further information www.haascnc.com

A second automated production cell has been installed at the Tamworth factory of Alcon Components to cope with worldwide demand for its monobloc brake calipers. The calipers are machined from aluminium or lithium billet for motorsport race cars and high-performance road cars, as well as from cast iron for military vehicles.

Similar to the original automated system installed in February 2007, the latest configuration is based on a bigger Hermle five-axis vertical machining centre, a model C32U with 650 x 650 x 500 mm axis travels, reflecting the fact that brake calipers have become larger over the past decade. Supplied by Geo Kingsbury, UK agent for the German machine manufacturer, the C32U has been equipped with an Erowa Robot Easy that stores 12, 210 mm diameter pallets, which are transferred to and from the working area by a horizontally travelling load/unload arm.
As on the previous Hermle C20U, the latest five-axis machine is equipped with Blum laser tool-breakage monitoring and length setting, Renishaw part probing, an 18,000 rpm HSK63 spindle, 80-bar through-tool coolant and a 117-position tool magazine. Swarf management has also been provided, consistent with unattended machining of light alloy parts. Designs are produced in SolidWorks, while Open Mind’s HyperMill CAM software is used for creating the cutter paths prior to program transfer to the Heidenhain control.
Brake caliper production is a natural application for five-axis machining, as Alcon discovered 10 years ago. Compared with four-axis metal cutting, it is not only faster but also inherently more accurate, as approach angles can be adjusted to allow shorter and hence more rigid tool holders to access awkward component areas.
For further information www.geokingsbury.com