FEATURE ON CNC MILLS & MACHINING CENTRES

CNC bed mills released by MACH Machine Tools

The new MACH MDM 700-AR and MACH MDM 1000-AR CNC bed mills provide customers with high cutting performance, life-long precision, built-in flexibility and unrivalled reliability at a cost that, according to Dave Andrew, managing director of Vigilance Group (of which MACH Machine Tools is part), “will make your jaw drop and the guys in accounts smile”.

Both machines feature BT 40 spindles (5,000 rpm), roller-type linear guideways and large worktables (up to 1525 x 350 mm for the larger MDM 1000-AR model). The machines deliver positional and repeatable accuracies of 0.006 and 0.003 mm, respectively.

MDM 700-AR/MDM 1000-AR machines are supplied with the established DynaPath CNC integrated with MACH Machine Tools’ free, 24/7, Wi-Fi enabled ‘Remote Assist’ facility.Remote Assist provides customers with expert applications and service support, including free software updates, for the life of the machine.

“With Remote Assist, the 20 minute maximum response time to customer queries means that machine downtime is kept to an absolute minimum, which is proving a massive draw for customers,” says Andrew.

The DynaPath control includes: conversational and ISO/G code programming capabilities, making it easy to program machines on the shop floor;64 Gb on-board storage and 10,000 block look-ahead capability that ensure fast processing speed complemented by improved accuracy and smoother surface finish; functions such as datum setting using alignment, sub-program calling, the use of macro-programming, the ability to facilitate program simulation using tool path or 3D rendered graphics, and programmable spindle control; a DXF and onboard DXF editor; and a multitude of communication methods, including Wi-Fi connectivity.

As with all MACH machines, MDM-AR models are supplied, as standard, with technology features that include: 15.6” touchscreens, manual pulse generators, air power drawbars and coolant equipment.

More information www.machinetoolsalesonline.com

Powermill HPC3 gantry mill destined for China

Among the gantry mills manufactured by Mecof for large components, the Powermill HPC3, built for a Chinese customer, combines power, precision and operational flexibility. This portal milling machine is designed to meet the complex needs of the electrical cable manufacturing industry, but with features that also make it suitable for other high-production applications.

With axis strokes of 12 m in X, 4 m in Y and 2.5 m in Z, the portal architecture of the Powermill HPC3, combined with its box-in-box design, ensures rigidityand thermal stability.The latest-generation Siemens Sinumerik ONE numerical control guarantees optimal cycle management and the digital integration of production processes.

One of the machine’s strengths is its ability to manage different interchangeable heads, all designed for automatic changeover.The universal bi-rotary head with automatic millesimal positioning offers ample power (38 kW), torque (1000Nm) and speed (6000 rpm) for complex machining operations, while the more compact vertical spindle head meets the need for precision and versatility. The latter offers 15 kW of power, 390 Nm of torque and a speed of 3000 rpm.Both heads feature an ISO 50 connection.

Productivity arrives courtesy of a 64-position tool magazine (two chains of 32 positions), integrated into the shoulder of the machine, with independent chains to maximise changeover speed. The machine also features a complete measurement and control system, which includes a Renishaw radio probe, kinematic measurement, and tools for checking tool length and diameter.

Intensive milling requires effective cooling. For this reason, the Powermill HPC3 destined for China is equipped with a dual cooling system, both external and internal to the spindle (up to 40 bar), 2000-litre collection and filtering tanks, and flow control devices.

More information www.bit.ly/4tFgmQu

Future is bright for Bronte Precision Engineering

Mills CNCrecently supplied Bronte Precision Engineering, a Bradford-based precision subcontract specialist, with a new heavy-duty three-axis vertical machining centre.The machine, a box guideway Mynx 6500/50 II manufactured by DN Solutions, replaced an older Daewoo Mynx 540 machining centre supplied to Bronte by Mills CNC in 2004.

Since its installation, the Mynx 6500/50 II with FANUC 0iMP control and gearbox-driven 6000rpm (BT 50) high-torque spindle has been put through its paces machining a range of high-precision complex components. These parts include valve-type components (for subsea applications) made from Inconel castings for a long-standing customer and manufacturer of industrial pumps.

Programmed offline and machined in small batches, the pump valve components are approximately 400 x 300mm in size, involve long and intensive roughing and finishing operations, and are characterised by their tight tolerances and stringent surface finishes. Cycle times with the new Mynx 6500/50 II are significantly faster (up to 50%) than those achieved using the Mynx 540, vindicating the new machine acquisition.

Says Bronte Precision director Steven Haigh:“The Mynx 6500/50 II is a powerful, accurate and flexible machining centre that, in just a few short weeks, has proved its worth. Its rigidity, box guideway construction and BT 50 spindle with through-spindle-coolant capability has enabled us to improve our productivity and process efficiencies.The ability to ramp up speeds and feeds and take more aggressive depths of cut have shortened cycle times.”

He adds: “The machine is still being ‘bedded-in’ so to speak, but I’m confident that once we’re more familiar with its onboard technologies, we’ll hit tolerances of ±0.03mm on selected features.”

More information www.millscnc.co.uk

Starrag Machine Achieves Unprecedented MRR

The Starrag S1250 HD five-axis machining centre with hydrostatic guides, which is suitable for machiningtitanium thanks to its rigidity and damping attributes, achieved astonishing results in performancetestsperformed by Starrag at its main plant in Rorschacherberg. Using a carbide cylindrical endmill (40 mm diameter, 18 teeth), the machiningspecialist achieved a metal removal rate (MRR) of 1516 cm3/min. Starrag estimates this MRR is potentially a world record in titanium machining.

Even the prototype of the Starrag S1250 HD proved to be a highly efficient machine for cutting titanium structural components. Two years ago, in roughing tests, the machining centre with hydrostatic guides achieved up to three times the MRR of the Starrag STC 1250 version featuring roller bearings. The improved damping and dynamic performance also ensured high precision and surface quality during finishing.

For the series-produced machine, Starrag engineers imparted a few additional modifications to increaseMRR further and reduce tool wear. As the most critical factors in this context are rigidity and damping, Starrag made the machine and column structure even more sturdy.

Another revision concerned the rotary table, which is now designed as a gearbox version. With a high torque of 25,000Nm and a clamping torque of 32,000Nm, it fully meets the requirements of titanium machining. In addition, the compact swivel milling head was enlarged on one side, creating space for a 50% stronger Aaxis with 12,000Nm of torque and 20,000Nm of clamping torque while retaining accessibility.

In terms of the work spindle, a new feature is the HSK-B160 interface, which ensures high tool rigidity when cutting large depths.

Airbus has already ordered five Starrag S1250 HD machines for its Varel site in Germany.

More information www.starrag.com

Five-Axis Machining Centre Options Include Ultrasonics

Occupying just 3.8 sq m of space on the shop floor, a compactfive-axis machining centre with a working volume of 220 x 370 x 290 mm is now available from DMG Mori. The new DMU 20 Linear can meet a wide range of applications, from the micro-machining of watch components, through EDM electrode and impeller production, to die and mould making.

A rigid, FEM-optimised cast bed and thermo-symmetrical gantry design have been coupled with Magnescale axis position measuring systems to ensure long-term stability and machining accuracy to within single-figure microns.

The A-axis trunnion swivels from +130 to -93°, allowing flexible machining strategies and enhancing the operator’s view of the workpiece. The C-axis table rotates at up to 150 rpm, optionally 1500 rpm, while offering a positioning accuracy of two arcseconds. Zero-point clamping is standard, with the customer able to choose Erowa, Schunk or another make. There is also provision for the vacuum clamping of delicate or thin-walled workpieces.

The machine features a Fischer spindle (HSK 32, 42,000 rpm) as standard, although HSK 32 or HSK 40 spindles up to a maximum of 60,000 rpm are available. If elevated levels of precision are necessaryin combination with long running times, a shaft-cooled version is available for the HSK 40 variant. The tool magazine offers 26 pockets, optionally up to 60 tools, suitable for flexible production requirements with frequent tool changes.

For machining hard, brittle materials such as glass, Zerodur or technical ceramics, the machine is available as a third-generation Ultrasonic 20 Linear. In this model, tool rotation is superimposed with an additional ultrasonic oscillation, reducing the force generated by the tool during machining by up to 50%.

More information www.dmgmori.com