FEATURE ON CNC MILLS & MACHINING CENTRES

Bryken trebles automated milling capacity

A long-time user of two automated machining centres that exchange parts fixtured on pallets, in 2022 subcontractor Bryken installed a Hermle C12 machining cell with an integrated RS05 robot for loading billets directly into the working area and unloading finished components. It was supplied by Kingsbury, the sole sales and service agent in the UK for the German machine manufacturer.

The installation was followed one year later by a second cell, this time with drawer rather than tray storage. A similar, even more advanced system with gripper exchange and vice jaw change system arrived in early 2024, allowing multiple different parts to run without operator intervention overnight and at weekends.

Bryken purchased the first Hermle cell after an oil and gas OEM placed an order for 600 new types of manifold, bringing the total number of different parts produced for this customer alone to nearly 1400. Almost all manifolds are made of 316 stainless steel.

The company’s director Phillip Taylor explains: “We don’t have any allegiances to machine tool suppliers, always choosing the most appropriate, high-quality kit for the intended purpose. We opted for an automated cell from Hermle as it was the only solution that was a true billet-handling, five-axis machining cell with a fully integrated robot. The other systems offered either had bolt-on component handling or were pallet-exchange configurations.”

At Bryken’s Knowsley factory, the Hermle cells work 24/7 and delivers an OEE above 90%. Taylor says that the machines hardly ever stop. The first two cells produce around 2000 parts per month. One machines about two-thirds of these components spread across 15 different part numbers, while the second has a more diverse workload involving smaller batch sizes.For further information www.kingsburyuk.com

A high-end HMC inside a small footprint

To accommodate the diverse needs of the marketplace, Starrag Heckert has introduced its new H Compact series of horizontal machining centres (HMCs). The benefits of HMCs can sometimes be overshadowed by the sizeable footprint of the machines in comparison to their vertical counterparts. However, with its H Compact Series, Starrag Heckert says it is delivering the benefits of a horizontal with a compact footprint that will appeal to manufacturers.

Looking at the merits of the new machines, Lee Scott from Starrag says: “These horizontal models feature a trunnion table with five-axis capability. We can also incorporate a high-speed table for turning, a configuration that gives us the ‘T’ range. In its basic guise, it’s a twin-pallet HMC with a monobloc mineral cast base that is very vibration-absorbent and stiff.”

The machine column has positive-leveraged ratios that are credit to maximum guideway distances, while weight compensation improves the performance, accuracy and efficiency of the ballscrew-driven Y axis.

Alluding to the pallet system on the new series, Scott says: “It’s a twin-pallet machine where the ground pallet surfaces ensure perfect interfaces for the fixtures, whether it be on a trunnion or a standard B axis. Outside of the machine, we have the set-up station. Thus, while the first pallet is working inside the machining area, the second pallet is either loaded by a robot, an FMS or an operator.”

Taking a closer look at the operator interface on the new H Compact series, the machine incorporates the latest FANUC or Siemens control.

“Operators love our system, it has a touchscreen and multi-screen facility that offers the perfect solution for engineers who want to get the maximum amount of data from the machines,” concludes Scott.

For further information www.starrag.com

XYZ machines elevate stairlift specialist

XYZ Machine Tools is helping Handicare to maintain the accuracy, rigidity and quality of its stairlifts by machining the mating surfaces of its tubular components using an XYZ RMX 3500 bed mill for straight sections and an XYZ RMX 4000 bed mill for curved sections.

Among Handicare’s UK manufacturing facilities is its Kingswinford, Birmingham plant, where the company designs and manufactures straight and curved stairlifts, producing more than 50 every day. The key element of each stairlift is a pair of tubular runners with welded gear racks. These support the seat and, with its pinion drive and rollers, allow it to transport the user smoothly and safely between floors.

Nabil Mohamed, production engineer at Handicare, says: “For straight stairlift sections, the tubes and gear racks are welded together by  a robot and cut to length. We leave an excess of 0.5 mm which we machine off using the XYZ RMX 3500. This process ensures that the gear profile on the rack is perfect when we join the tubes.”

The XYZ RMX 3500 is dedicated to straight sections and has a set of fixtures on the bed, each designed to lock into the gear profiles and position the tube in the exact position required to mill across the end and generate an accurate gear profile and tube length. The open design of the bed mill makes it possible to work with long tube sections that overhang the bed.

For curved profile stairlifts, the process is similar with tube sections machined on the XYZ RMX 4000. This machine has a larger bed of 1474 x 355 mm and fixtures loaded to suit the end-machining of curved sections.

For further information www.xyzmachinetools.com

Deal signed for largest UK robots

Aerospace automation specialist Loop Technology has signed a deal with FANUC UK for
seven new robots – including the largest industrial robot ever ordered in the UK, the FANUC
M-2000iA/1700L. Three FANUC M-2000iA/1700L six-axis robots will be delivered to the
University of Sheffield Advanced Manufacturing Research Centre (AMRC) for its new
innovation facility in South Yorkshire.
Part of Project Compass (Composites at Speed and Scale), the Loop/AMRC deal also
encompasses two further FANUC M-2000iA robots: a 1200L and a 900L model. As part of a
separate project, another 1700L model, along with an additional 900L unit, have been
ordered by Loop Technology to form part of a high-rate composite preforming cell for a
North American aerospace client.
For further information www.fanuc.eu

Injection mould maker automates machining

Based in Budapest, Euroform provides an injection mould-making service from design to
production. The firm currently uses eight machining centres from DMG Mori for tool
production, including DMU monoBLOCKs, an HSC 75 linear and, most recently, a DMU 100 P
duoBLOCK. The latter features a PH Cell 2000 automation system for pallet handling to allow
unattended production at night and during the weekends.
The five-axis simultaneous machining of workpieces up to 1100 mm in diameter by 1600
mm long and weighing 2200 kg has already taken place on a DMU 100 P duoBLOCK.
Euroform’s experience with the machining centre was consistently good, leading to the
purchase in 2022 of a latest-generation model with a 1000 × 1250 × 1000 mm working
envelope.
When Euroform ordered the new DMU 100 P duoBLOCK, DMG Mori already had a large
pallet handling system in development, based on the smaller PH Cell 300. The bigger
capacity automation system handles pallets measuring up to 1100 mm in diameter, so is
able to deploy Euroform’s 1000 × 800 mm pallets. The PH Cell 2000 has 12 pallet positions
on two levels and can accept workpieces up to 1350 mm tall.
As Euroform almost exclusively manufactures one-offs, pallet handling such as the PH Cell
2000 is the optimal solution. Operators set up jobs offline on several pallets using a zero-

point clamping system while machining is in progress on another mould, so production
downtime is minimal, even at night.
Another focus area that supports business development at Euroform is digitalisation. The
mould maker is an enthusiastic adopter of the digital ‘my DMG MORI’ app when it comes to
online service requests.
For further information www.dmgmori.com