FEATURE ON CNC MILLS & MACHINING CENTRES

Small five-axis machine packs real punch

Mills CNC, the exclusive distributor of DN Solutions (formerly Doosan) and Zayer machine tools in the UK and Ireland, has introduced a new simultaneous five-axis machining centre.The DN Solutions DVF 4000 is the latest addition to the company’s best-selling DVF-series of five-axis machining centres and, with its compact size and technical specification, targets component manufacturers looking to improve their productivity and process efficiencies.

The DVF 4000 is powerful, fast, flexible and reliable, reports Mills CNC. It is suitable for processing parts that require multiple machining operations,reducing the number of set-ups required to produce such components to completion.The machine comes with a 12,000rpm (BT 40) directly-coupled spindle as standard, powered by an 18.5kW motor that generates 118Nm of torque. AFANUC 31i-Plus control enables machine shops to use the DVF 4000 in full simultaneous five-axis machining mode with advanced contouring capabilities.

Notably, the DVF 4000 is equipped with a 400mm diameter, integrated rotary tilting table with a zero-backlash roller gear cam design that delivers improved speed and reliability.
Productivity and process efficiencies are further realised with the machine’s 60-tool, servo-driven automatic tool changer and an integrated thermal compensation system, comprising six sensors strategically located within the machine that combat thermal drift issues in real time.

Roller LM guideways deliver improved speed and rigidity, while linear scales on the machine’s X, Y, and Z axes, and rotary scales on its B and C axes, ensure accurate positioning and repeatability.
For further information www.millscnc.co.uk

XYZ helps PJ Innovations make lots of dough

Market Deeping based PJ Innovations makes dough divider-rounder machines (and theirassociated spare parts) for the bakery industry. When the company formed in 2014 it subcontracted all component manufacturing requirements. However, PJ Innovations started investing in XYZ Machine Tools in 2016 to bring some of the work in-house.

The company’s first purchase was an XYZ Proturn SLX 425 lathe with ProtoTRAK control, which it uses for turning large shafts 90mm diameter and 1m long in batches up to 100.The Proturn SLX 425 is a gap-bed lathe with a capacity of 2m and swing over the bed of 480mm. The extra length gives options for longer shafts. Notably, the operator has 20-30 tools ready set, so switching between programs stored in the control unit takes just 5-10 minutes.

For frame plates and the many parts which require lots of drilling, tapping and boring, the company takes advantage of an XYZ SMX 5000 with ProtoTRAK control and 1930 x 356mm table. Programming takes place at the control and fast changeover between jobs makes this machine suitable for 1-offs and low batch sizes.

The most recent acquisition is an XYZ 1000 TMC with ProtoTRAK RMX control. Manufacturing manager James Goode says: “The tool changer speeds machining up a lot and the enclosed cutting area is better from a safety and cleanliness perspective. We also like the handwheels on all XYZ machines, which allow us to move backwards and forwards through a program to prove it out. You can easily learn to program the ProtoTRAK in one day.”

PJ Innovation’s new XYZ 1000 TMC is for component batches of up to 50-off that need drilling, boring and tapping. Additionally, tool setting is easy using the touch probe, with offsets recorded in the control by pressing the ABS set button.
For further information www.xyzmachinetools.com

XYZ streamlines medical device development

ATL Technology in Cardiff is a specialist manufacturer of medical devices, particularly energy-driven instruments used in minimally invasive surgery. These devices use low-voltage, high-current RF energy waveforms to seal, coagulate, dissect, vaporise, resect or mobilise tissue. ATL utilises two tool rooms to produce prototypes, tooling, jigs, fixtures, special in-house machinery for assembly and disassembly, and spare parts.

The R&D toolroom initially adopted an XYZ SMX 2500 bed millin 1997. Over time, the company expanded its capabilities with the addition of a 660 HD vertical machining centre, a 1340 lathe and an XYZ 500 LR vertical machining centre featuring linear rail technology.

Meanwhile, the maintenance tool room utilises an RLX 1630 lathe, an XYZ 1500 manual turret mill and an XYZ RMX 2-OP, which machines light alloy and plastic parts from stock materials. The recent acquisition of an XYZ 500 TMC in March 2023 further highlights ATL Technology’s long-standing investment in XYZ machines.

Process development engineer Stephen Greensays: “The XYZ 500 TMC has a larger working area that enables us to machine bigger mould tools, jigs and fixtures in-house. It has more power, a 12,000 rpm spindle that is ideal for small tools, and through-tool coolant. This capability makes it easy to machine tool steels for injection moulds and electrodes for die sinking. It is also good at deep-hole drilling, delivering faster material removal rates. Withsubcontracting, it took many weeks to deliver a tool. Now we can produce an entire tool within a week, or a single part to repair a production line breakdown within 24 hours.”

Tool-room technician Ashley Gardiner adds: “90% of our work is one-off, small batches or spares, so the 12 tool pockets on the 500 TMC are sufficient for most of our needs.”
For further information www.xyzmachinetools.com

Gear hobber offers three configurations

When developing the AF160, maximum versatility was the key goal of the engineering department at the Swiss family enterprise Affolter Group, a specialist in high-precision gear-hobbing solutions. As a result, three gear-hobbing configurations are available.

With the optional quick-change system, machine operators can switch from one configuration to the next in only 30 minutes. In configuration I, both the C axis and the C’ prime axis are equipped with driven spindles. This set-up leads to increased cutting quality, more torque and higher rigidity. In addition, the set-up offers an A axis of±50° swing, making it ideal for the production of spur, helical, bevel, crowned and face gears.

With a tailstock on the C axis and a spindle on C’ prime axis (configuration II), the operator gets more flexibility. The A axis can move from -50° to +115°, making worm milling possible. This configuration is also suitable for all gear types mentioned above. In configuration III, the C axis remains empty and the C’ prime axis features a driven spindle. As a result, users can undertake thepower skiving of internal gears and the production of face gears.

TheAF72 part loader features a double gripper system for parallel loading and unloading, and a telescopic arm. Customers can select different configurations depending on the volume, product and application. It is possible to equipthe AF72 with up to five feeding rails, enabling users to preload more parts and let the machine work autonomously for more than 24 hours.

The AF160 is configurable for any application. Hobbing options include skiving by sensor detection, and integrating a deburring process into gear production with the addition of the AF54 deburring unit.
For further information www.affoltergroup.ch

Machining centre choice made pure and simple

Mills CNC has supplied Pure Innovate Manufacturing, a project management and engineering solutions provider, with a new high-performance machining centre.The machine, a DN Solutions DNM 5700 is now in-situat the company’s new and spacious ‘Innovation’ facility in Wallingford, just a few days after relocating its operations there. It is the first machine tool acquired by the company in its four-year history.

The DNM 5700 acquired by Pure Innovate is a three-axis vertical machining centre equipped with FANUC iPlus control and 15” touchscreen iHMI. Further features include an 18.5kW/12,000rpm directly-coupled spindle, 30-position ATC, large worktable and fast rapids. Mills CNC supplied the machine with through-spindle-coolant capability and a Renishaw tool and workpiece probing system to increase machining flexibility and improve process efficiencies.

Pure Innovate is the brainchild of managing director, Carl Joy, who says: “Having our own dedicated machining resource at the Innovation facility improves our flexibility and responsiveness.We’re can produce prototypes [including any iterations] quickly and efficiently – and means we’re not only able to deliver high-quality, fast turnaround machined prototypes, but also the processes developed and used to machine them.”

He continues: “To increase the scope and scale of our Innovation facility in the future, we are actively looking at investing in new technologies, like simultaneous five-axis machines, and developing our in-house capabilities further through processes such as additive manufacturing and composite machining.Nothing is off the table.”

Joy took the decision to invest in a DN Solutions DNM 5700 for a number of reasons.

“Pound for pound, the DNM 5700 is the ideal machine for us,” he states. “The machine is fast, flexible and accurate. It will enable us to machine high-precision prototypes and pre-production parts quickly.”
For further information www.millscnc.co.uk