FEATURE ON CNC MILLS & MACHINING CENTRES

Adams slides into three-axis machining

Although a predominantly sliding-head turning machine shop, Adams Engineering (Ilkeston) Ltd has just purchased a Dugard 1000XP three-axis machining centre. Initially founded in the 1950s and run as a single-cam auto machine shop for decades, the business has more recently been taken over by Scott Burrow. Since the takeover, the company moved to new and larger premises three years ago and continued its machine acquisition trail.

Discussing why Adams Engineering has invested in three-axis machining, Burrow says: “Our first venture into milling was down to one of our customers. They kept pressing us to do milling work, so eventually we took the plunge. With the first machine we bought, we were initially just drilling and tapping prismatic parts and putting steps in plates.”

As word got around that the company was undertaking milling work, more enquiries flowed in.

“Due to rising enquiries we bought a larger machine, the Dugard 1000XP three-axis machining centre,” explains Burrow.

The ISO9001-accredited company wanted a machine with a sizeable capacity and a robust platform, which is exactly what the Dugard 1000XP delivers. As standard, the machine has X, Y and Z-axis travel of 1050 x 540 x 560mm to accommodate large parts. It also offers a 27kW BT40 spindle motor, a cartridge belt drive spindle and pre-tensioned twin-nut ballscrews.

“We just thought, why not go big.Today, we are doing work that takes up almost all the entire bed.”

The Dugard 1000XP has X, Y and Z-axis rapid feed rates of 44, 44 and 25m/min, with a cutting feed rate of 20m/min credit to the Mitsubishi CNC control system. Positional accuracy is 0.01mm, while repeatability is ±0.003 mm.
For further information www.dugard.com

Five-axis machining centre is automation-ready

A new, horizontal-spindlefive-axis machining centre is now available from DMG Mori that the company says can maximise productivity when machining complex workpieces weighing up to 1 tonne. The robust INH 63 has a working volume of 1070 mm diameter x 1000 mm high and a maximum pallet size of 630 x 630 mm. Due to its compact dimensions, it offers easy integration into automated production systems.

Dies, moulds, battery boxes for electric vehicles and aerospace valve bodies are typical components that the machine might produce. Its stable design with a symmetrical structure optimised by FEM and twin ballscrews in all orthogonal axes, promotes precise and dynamic milling. Magnescale linear encoders result in high positioning accuracy, while reliable cooling of the ballscrews and other sources of heat suppresses thermal displacement and changes in the machine structure.

Compared with the previous model, the INH 63 offers 65% more cutting capacity. For five-axis machining, the INH 63 swivels the rotary table from + 45 to -195°, with direct-drive motors providing speeds of 90 and 30 rpm respectively. The PowerMaster spindle delivers 12,000 rpm, 808 Nm and 85 kW, while a version with up to 16,000 rpm or 1414 Nm at 8000 rpm is optional for heavy-duty cutting. For Master spindles, DMG Mori provides a warranty of 36 months with no run-time limit.

The wheel magazine, which offers 63 tool positions as standard, is expandable to six wheels, providing space for 363 tools up to 320 mm in diameter by 700 mm long and weighing 35 kg (optionally 50 kg). The high capacity allows long periods of autonomous operation if integrating a large pallet storage solution.
For further information www.dmgmori.com

Toolmaker diversifies into five-axis machining

Located in the centre of Birmingham, press toolmaker Tooling 2000 began trading more than 50 years ago. Since 1996 it has focused mainly on the design, production and try-out of tools for the automotive industry, notably for Jaguar Land Rover, Nissan and Rolls-Royce/Bentley.

With a view to strengthening its position in the industry and breaking into the provision of subcontract machining services to other sectors, such as power generation and renewables, the company has invested £1.8m in the past two years in new plant and hiring extra people.

A significant proportion of the spend has gone on acquiring new machine tools from Hurco, including the toolmaker’s first two five-axis machining centres, VMX60SRTi and VMX42SRTi models.The SRTi configuration is rapidly becoming Hurco’s most popular five-axis model. The torque motor-driven, swivelling B-axis spindle head and 600 mm diameter Caxis set flush into a fixed machine table create a compact, high-capacity platform that can serve as a large-capacity three/four-axis machine whenever required.

Tooling 2000’s manufacturing director Brian Abbott says: “In recent yearswe’ve seen growing demand from customers for the supply of more complex components that require five-axis machines to produce them cost effectively.The technology was a step into the unknown for us, so the availability of support from the machine supplier was paramount. As an existing Hurco user, we were comfortable with sourcing our first five-axis machines from them, particularly in view of the user-friendly, twin-screen controls.”

Machine operator Dean Henning adds: “Hurco machines are best suited to our type of work because the conversational control with WinMax software is easy to use and we can program most jobs on the shop floor. Even on the 5-axis models we can use the Hurco control to program 3+2-axis cycles.For more complex work, the option of inputting a DXF file from CAD into the Hurco control and using the drawing as the basis for creating the part program is especially useful and fast.”
For further information www.hurco.co.uk

Nakamura extends next-level machining

Following hot on the heels of the new Nakamura-Tome SC-200II machine that recently launched as an evolution beyond its predecessor, the SC-200, Nakamura is now introducing the new SC-200IIL. This latest iteration is available in the UK from the Engineering Technology Group (ETG).

The SC-200IIL turning centre inherits many of the main specifications of the SC-200II and its concept of ‘next-level machining’. However, the SC-200IIL expands the distance between centres, evolving into a machine capable of producing long workpieces. This development allows users to select the R-side specifications from the sub-spindle or NT tailstock units. While the SC200II has a maximum turning diameter of 390mm and a 510mm distance between spindles, the new SC-200IIL increases this distance to 715mm between centres, with 800mm between spindles.

Like the SC-200II multi-tasking lathe, the SC-200IIL provides a powerful and stable machining platform under challenging conditions. Despite the machine being in the 8” chuck size class, it has a swing over the bed of 620mm diameter, providing a large machining area for a small footprint machine.This configuration also enables the machine to accommodate a 10” chuck if required. The output of the spindle motor is now to 15/11kW, with the option of an 18.5/15kW motor.

Similar to the SC-200II, the SC-200IIL has high acceleration rates that enable the operator to machine larger parts and expand the scope and variety of components considerably.

Nakamura-Tome CEO Shogo Nakamura says: “Since this machine is capable of processing large billets and bars that would normally require a machine one size larger, the SC-200IIL has arrived to deliver favourable changes to factory floors.”
For further information www.engtechgroup.com

Expediting production of high-precision blades

GF Machining Solutions (GFMS) recently introduced, via its Liechti Engineering AG subsidiary, a high-performance simultaneous five-axis machining dedicated to the fast and efficient processing of high-precision blades used in the aerospace and power generation industries. The Liechti Turbomill 500g, with a whole host of features that include Liechti’s g-technology and ‘Tool Pivot Point’ machining capability, helps manufacturers machine high-quality, competitively-priced blade components in double-quick time, reports the company.

The machine, equipped with a 20,000 rpm HSK-A63 StepTec spindle and up to 2000 rpm turning capability, boasts 2 g acceleration/deceleration rates and 60 m/min linear feed rates, ensuring that the Turbomill 500g gets down to business fast. According to GFMS, the machine helps to reduce part cycle times by up to 30%.

These ultra-fast processing speeds do not compromise accuracy or quality as the Turbomill 500g can achieve blade accuracies of ±0.015 mm, and surface finishes of 0.4 µm. To ensure high-productivity through unattended operation, users can opt to equip the Turbomill 500g with a bar feeder that automatically loads bar stock into the machine.

For consistent, high-quality part production, the machine features direct-drive motors (on all five axes), as well as an internal bed cooling system and intelligent thermal compensation that helps stabilise machining temperatures and reduce the effects of thermal drift. The machine is also equipped with Liechti’s 100 rpm Tool Pivot Point innovation which, available on the machine’s B axis, ensures fast and accurate contouring around blade edges. Reduced movement of the linear axis delivers shorter cycle times, higher positional accuracies and less mechanical wear.
For further information www.gfms.com