A recognised manufacturer of barfeed systems for CNC lathes, Milton Keynes-based Hydrafeed is also a subcontract machinist for the aerospace, special purpose machinery and tobacco machinery sectors. To meet the machining demands of both sides of its business, the company has extensive machine shop capacity, ranging from manual machines through to CNC machining and turning centres. Sitting central to this capacity are four XYZ ProtoTrak-controlled machines.

Hydrafeed has been in operation for almost 50 years as a family-owned business with current managing director Martyn Page joining the company as a toolmaker 35 years ago. In 2012, along with his wife and son, he took the opportunity to buy Hydrafeed and maintain that family-owned tradition. Along the way, the barfeed element of the business has grown, with around one unit per day being dispatched. In addition, robotic automation for machine tools is now part of the Hydrafeed portfolio.
The company’s barfeed systems are sold mainly through OEM machine tool suppliers, such as XYZ Machine Tools. However, the resulting ongoing investment in machining capacity to meet the needs of barfeed production, meant that machines were sometimes underused. With this in mind, Hydrafeed expanded its operations to offer a subcontract machining service.
“Our subcontract work is tightly controlled and we manage the type of business we take on quite closely; focussing on regular customers with none of them dominating our capacity – the old 80/20 rule applies here,” explains Page. “Over the years we have continued to invest in machining technology, but like many, we have faced the skills challenge. Helping to overcome that are the four XYZ machines, which sit perfectly between our manual capacity and our CNC machining and turning centres. The ProtoTrak controls on the XYZ mills and lathes are straightforward to use and we have been very pleased with them. They are perfect for one-offs and smaller batch work.”

The XYZ machines installed at Hydrafeed are an SLX355 ProTurn lathe, an SLX 1630 ProTurn lathe and two SMX 2000 ProtoTrak turret mills. All four feature the ProtoTrak conversational control system, which is said to be notable for its ease of use. According to XYZ, operators who are new to CNC can be programming fairly complex parts with just a few hours of tuition.
On the SMX 2000 turret mill, the control is available as either a two- or three-axis system, with canned cycles to produce features such as various shaped pockets (including pockets with islands), thread milling, bolt-hole patterns, drilling, tapping and boring. ProtoTrak SMX also features its novel ‘guess’ button. If a dimension is missing from the drawing, the user can simply estimate the approximate position of a point or intersection, press the ‘guess’ button, and the control performs the calculation. Further advantages include 3D surfacing with on-board DNC, and the capability to handle virtually unlimited program size.
For its ProTurn lathes, XYZ uses the SLX variant of the ProtoTrak control, which also has many benefits in relation to ease of use. As with the mills, the control allows both manual and full CNC operation, with a key feature being the ‘Traking’ facility that is standard on all XYZ ProTurn lathes. Traking is one of a number of ways that the ProtoTrak control allows the verification of a program. Using this feature, the operator can work through the program using the two hand wheels. Traking can be used in such a way to go through the entire program or, up to a point where the operator is confident to stop the feature and press cycle start. Traking can be re-engaged at any time during the cycle. In addition to conversational, at-machine programming, which is said to allow even complex parts to be programmed in a matter of a few minutes, CAD drawings can be converted into programs using the optional on-board DXF file converter.

“Our sub-contract work continues to grow, and we occasionally need to call on others to help with over-capacity issues,” concludes Page. “This is where the value of our customer/supplier relationship with XYZ Machine Tools comes in. Talking with our XYZ area sales manager, he was able to point us in the direction of another XYZ customer, DJM Engineering, who had similar machines and skill sets to Hydrafeed, and this gave us the confidence to place work with them in the knowledge that they could maintain the delivery and quality which we expected. This is a great example of networking between businesses with similar work ethics to ourselves: being good at what we do and enjoying it at the same time.”
For further information www.xyzmachinetools.com

Based in Sutton-in-Ashfield, Nottinghamshire, R&D Leverage provides technical solutions to the European plastic packaging industry. The busy company serves a wide range of demanding sectors, including the food and beverage, medical, cosmetics, household and personal care markets.
The work of R&D Leverage UK, together with that of R&D Leverage USA, has enabled the business to develop into one of the foremost providers of quality tooling for the world’s packaging industries. At its UK plant, the company produces single-stage, injection stretch blow mould (ISBM) tooling for PET containers.

Certified to BS EN ISO 9001:2000, R&D Leverage UK is equipped with a range of innovative design, production and inspection aids that help ensure the delivery of on-time, on-budget moulds. For instance, the company’s machine tools are used to deliver the quality and accuracy required by customers. Indeed, R&D Leverage UK believes that purchasing the best available, most productive machines provides the levels of efficiency that enables it to compete in what is a fiercely competitive sector. This philosophy is reflected in the company’s most recently installed machine, a Studer S31 cylindrical grinder from Micronz, the second such model on site.
Having been delighted with the performance of the company’s first Studer S31, ever-increasing demand for the company’s moulds recently prompted the purchase of a second machine from the Swiss manufacturer.
R&D Leverage UK’s managing director Alan Tolley says: “From our high-tech Sutton-in-Ashfield plant we are a complete solution provider for a wide range of packaging sectors across Europe and beyond. We’ve established an excellent reputation for the reliability of our products and for our use of the best available technology. When investing in machine tools, our aim is to maintain high quality standards and, mindful of our constant quest for further efficiencies, to enable the manufacture of our moulds to be achieved faster than before.
“Before purchasing our first Studer S31 grinder we searched for a machine that would satisfy both our quality and our efficiency requirements,” he continues. “Having witnessed demonstrations of several suitable machines, we decided that the Studer S31 ticked all of our boxes. We specified the machine to match our exact needs and, given the good reputation of the Studer brand, we were pleasantly surprised that the supplied quote was very close to the cost of other, less capable grinders.
“Following its installation, the ease of use of our first Studer grinder meant that it was soon turning-out the promised volumes of ground components with excellent dimensional and surface-finish characteristics. Since this time, the grinder has maintained it impressive performance and has proven to be extremely reliable.
“When demand for ground parts recently increased further, our positive experience with the first S31 and the excellent service we received from Studer UK agent Micronz, meant that we remained loyal to the brand. Once again, we were able to work closely with Mark Maurice, the owner of Micronz to specify a Studer S31 grinder that matched our evolving needs. Now fully operational, our new S31 is today producing the expected high volumes of premium quality ground components and has removed the potential for bottlenecks in our grinding department.”

The compact Studer S31 CNC universal cylindrical grinding machine, as purchased by R&D Leverage, is designed for the grinding of medium-sized workpieces with external and internal grinding in a single clamping. S31 grinders are able to grind workpieces in 1-off, as well as small and large batch production runs. Furthermore, the S31 can be adapted precisely to the demands placed on it; flexibility that is said to guarantee an optimal price-to-performance ratio.
Offering the ability to machine workpieces with a maximum weight of 80/120 kg, Studer’s S31 has distances between centres of 650/1000 mm, a centre height of 175 mm and
a grinding wheel diameter of
500 mm.
The machine’s solid Granitan base forms the bed of a cylindrical grinding machine that is equipped with quality components. In addition, the material structure developed by Studer, which has proven its quality over many years, is produced at the company’s own plant in Thun, Switzerland. The good cushioning behaviour of the S31’s machine base ensures surface quality of the ground workpieces and an increased service life of grinding wheels, further reducing downtime.
Studer’s S31 has a full enclosure that allows the use of emulsions or oils as cooling lubricants, while two large sliding doors provide operators with easy access. For automated, 24-hour running, handling devices can be connected via the machine’s defined loader interface.
The S31’s longitudinal and cross slides, as well as the V and flat guideways, have a non-abrasive Granitan S200 coating and are moulded directly into the machine base. These guideways offer precision throughout the machine’s entire speed range, along with with high load capacity.
A swivelling wheel-head enables the external, internal and form grinding of workpieces in a single clamping. Furthermore, the wheel-head is equipped with a water-cooled, maintenance-free motor-spindle mounted on roller bearings, featuring infinitely variable speed control. External grinding wheels with a diameter of 500 mm and a width of 63 mm are fitted to the shaft ends. High-frequency spindles with an external diameter of 120 mm are used for internal grinding.
The S31 also features a frequency-controlled, motor-driven grinding spindle for external and internal operations, while the machine’s C-axis work-head enables form and thread grinding.
Studer’s grinding software, with its ‘pictogramming’, allows less experienced users to quickly optimise the full potential of the S31. StuderGrind software is also available, enabling programming of special applications, such as form and thread grinding.
For further information www.micronz.co.uk

Steinel Normalien AG, a specialist manufacturer of cylinders, guides, springs, plates and die sets for the tool-making, stamping and forming industries, imposes the most rigorous precision requirements upon its manufacturing department. When the company introduced a new mill-turn centre, this manufacturer of pneumatic spring and composite systems was intent on streamlining its work-holding processes, so the 150 employee company sought its solution from Hainbuch.

Steinel was aiming to significantly reduce its set-up and throughput times, but the company with 25,000 different stock items and catalogue products recognised that it was not as flexible as desired. The company exerted significant time and effort with changeovers from jaw chucks to other clamping devices, however, thanks to Hainbuch, these times are now gone for good.
The combination of a new mill-turn centre, new clamping devices from Hainbuch and new machining strategies have increased manufacturing flexibility significantly. Now, a wider variety of parts can be machined and many processes eliminated, while three previous machine tools have been replaced with just one. The two men responsible for the project, Michael Tresselt, head of process development and James Hepfer, shift supervisor, recognised that the machining concept needed a rethink.
“With the new turning concept we wanted to achieve higher flexibility and optimise the set-up procedure. In order to quickly change the clamping devices on the new mill-turn centre, quick change-over systems were required. We carefully examined several system suppliers and their clamping solutions.”
Thomas Helfer, a Hainbuch sales representative, made a routine visit to Steinel and both men were very satisfied with the clamping devices and clamping heads from Hainbuch, which were already in use at Steinel. This larger project required a significant investment, and both Tresselt and Hepfer were not 100% convinced by the solutions they had seen previously. Competition was narrowed down to two suppliers, as Tresselt reports: “We then prepared an evaluation matrix of the available quick change-over systems. After a more precise test, Hainbuch’s flexible and highly accurate clamping devices convinced us. In particular, Hainbuch scored high with its insensitivity to contamination and repeatability.”
Hepfer explains the difference between the two leading change-over systems: “With Hainbuch’s competitor, the system works with a pull action. In comparison, the Hainbuch system does require screw turning, but the clamping device is more accurate and rigid. There are only six screws and they only need to be loosened slightly, which is why the procedure takes almost no time. The competing product has problems with its contamination sensitivity. Even if tiny dust particles get in the system, accuracy and rigidity suffer. The Centrotex interface from Hainbuch completely convinced us.”

Tresselt adds: “For change-over accuracy, Hainbuch provides 2 µm precision, while the competition specifies 0.01 mm. This difference is of absolute importance as our workpieces have strict parameters that we must keep. Moreover, with Hainbuch we get everything from a single source. With the Centrotex quick change-over system on the main and sub-spindle, we use a hexagonal Toplus chuck size 100 and a size 260 jaw chuck. This makes us extremely flexible and everything is interchangeable.”
With Hainbuch, Villingen-Schwenningen-based Steinel has certainly adopted the right clamping devices and impeccable level of accuracy for the high-precision manufacture of its guides and pneumatic springs. In addition, cube cast parts that require interrupted machining can also be machined on the new turn-mill centre. These parts were previously manufactured on two other machines using a time-consuming jaw-chuck process. Hepfer recalls: “The parts were turned and then milled, which obviously required two set-ups. Hainbuch recommended a mandrel for this clamping situation and we gave them a sample part for a turning trial.”
Tresselt adds: “We were not sure whether with the Mando mandrel would deliver on what Hainbuch promised. But we were surprised at how tightly, rigidly and accurately the mandrel performed. We now save one operation, as well as the change-over time. This significantly shortens throughput times, while parts can also be machined very easily thanks to the minimal interference contour of the mandrel. We like the Mando system a lot and now we are even considering what other workpieces we can clamp with the mandrel.”
Steinel places a high priority on flexibility because batch sizes for the standard cast parts and pneumatic springs are small. However, with the new concept, Steinel wants to further reduce batch sizes in order to respond more effectively and with greater flexibility to customer requests.
Tresselt says: “When the new programs run at their optimal level on the machine, we will further reduce the batch sizes. Now, with the new clamping devices, we are saving over 60 minutes every day. There is still space to improve. For our employees, the handling with the new clamping devices works perfectly. We have also purchased the compatible Monteq changing fixture and two storage containers. This ensures everything is cleaned-up and on hand for our employees.”

Service is the highest priority for Tresselt and regarding the support from Helfer, Tresselt concludes: “If we have a problem, we can count on Hainbuch. Moreover, Hainbuch provides us with free parts to run our trials. This cannot be taken for granted. Before we make a decision and place an order, we like to check and test everything. Now, we are re-ordering the same Hainbuch clamping devices for two other machines with bar loaders and Hainbuch is certainly our first port of call in the future.”
For further information www.hainbuch.com

An injection mould manufacturer has seen a recent resurgence of tool making in its native Irish Republic, and says CAM software helped it through the recession by giving the company a competitive edge to work in high-end markets.

Alpha Precision, based in Tubbercurry, County Sligo, operates an almost full suite of VISI modules, which director Brendan Feely describes as a seamless communication tool.
“Several years ago Ireland experienced an exodus of tool-making contracts as work went overseas, particularly to China. At the same time, VISI CADCAM software for the mould and die industry was rapidly developing and adding new features. Even companies which weren’t computer literate were investing in the technology to survive. The software had a huge effect on the tool-making industry, giving us a competitive advantage to weather the storm.”
He says it’s now “high end all the way” for Alpha Precision – high-end staff building high-end mould tools with high-end software. “The technology promotes a more automated process, and means our staff need a different skillset nowadays, to use VISI to its full potential.”
To explain fully how he feels VISI is the seamless communication tool that acts as the glue in the complete tool-making environment, he likens his tool room to a football team. “We need our goalkeeper, defenders, midfielders and strikers. We have a variety of different machines doing different jobs, so our operators have different skills. The software is applied on the back of the machining, and because there are several disciplines, such as design, milling, wire and spark eroding, the software fits naturally into its given area. The operator in that area is just trained on the one particular VISI module.”
Continuing the “team” analogy, Feely says the tool room is like a group of people from different countries with none of them speaking a language other than their own. “One language is design, with others including flow analysis, milling, wire EDM and spark erosion. VISI is the common language that unites all processes, ensuring everything moves fluently through the tool room from one discipline to another.”

Operating with 12 employees, the company produces an average of around 40 tools a year, ranging in size from 100 x 100 mm, up to 600 x 1000 mm, mainly for the automotive, medical, packaging and electronics sectors.
Two of the company’s current projects are: producing a number of high cavitation tools for one of its many medical customers; and a contract for two-shot plastic injection tools, which involves an over mould. “Although two-shot production adds another element by involving a second material and process, VISI keeps it simple and efficient.”
With VISI programs running the company’s high-speed milling on Röder and Makino machining centres, the challenges posed by the medical industry’s requirement for very fine micro levels, are readily overcome. “We use a 42,000 rpm spindle speed for very small detail finishing, and cut our electrodes on a Makino F3, with high definition being done on an F5. And we can also machine a cavity in just one night, which would otherwise take a week. Using VISI Machining we can quickly produce a highly polished medical part with fine detail, a milled finish and a split line, within micron accuracy.”
VISI also powers Alpha Precision’s Charmilles EDM machines for spark eroding and Mitsubishi wire eroders. He says parts of the tool will have been cut on each of the machines, and when it’s ready for shipping it is a very fine micron, accurately finished tool for, typically, the medical or automotive industry.
Having invested in many VISI modules including Modelling, Analysis, Flow, Mould and Progress, wire cutting and electrode systems, along with 2D Milling, 3D Milling and High Speed Milling, the software is used at every stage of the company’s process, beginning with providing an accurate quotation for the customer. “We use VISI’s analytical tools to check the drafts and all the different features we’ll need to build into the mould, such as the core and side pieces.
“When the order’s been placed, we work closely with our customers’ moulders on the design concept, including flow analysis and tool layout. Once the 2D design is broken down and we have the tooling in full 3D, we really begin to see the huge power of VISI, which controls everything from design, through milling to wiring in one environment. As we’re not going across translators there’s a perfect understanding within the technology, taking it right through every stage.”

Combining VISI’s Compass technology with its 2D and 3D milling capability, all milling for hard prepping and high-speed finishing is handled quickly and accurately, which Feely says is vital to the company’s operation. “We make a lot of one-off components for each mould, meaning we only run a program once. As pattern cutters we need to be very good at generating CNC code time after time, and VISI is exceptional at doing that job for us.”
Although injection mould tools form Alpha Precision’s core business, the company also provides a blow-moulding and forming-tool service, and has experience in specialised press tooling. However, Feely concludes by saying that the business is currently embarking on an exciting new journey, working closely with a major customer on injection rubber.
For further information www.visicadcam.com

Davturn, a small family-owned precision subcontract machinist based in Bromsgrove, has found increasing its production capability by installing a Miyano BNE-51SY6 turn-mill centre has added fuel to the burning desire to expand the five-people business into larger premises. As a result, managing director Mark Birley maintains, such has been the impact of the new machine that moving premises will then allow further Miyano installations by Citizen Machinery UK to increase its operational capability.

“We installed the multi-axis 51 mm bar size Miyano BNE-51SY6 in June to join our existing Miyano BNA-42DHY, which had already proven to be a success for the business since its installation in 2012,” he says. “At that time, it enabled us to increase the size of bar we machine from our bank of five sliding-head machines, which limited our capacity to 32 mm. Now, with 51 mm capacity, this immediately brought in a host of new orders.”
Birley has been entrenched in turned-part machining since he left school, which led him to take his skill and set up Davturn 13 years ago, basing the business on his experience in cam autos. He bought his first CNC machine in 2007, which set the firm on its steady growth pattern, and in the same year was joined by his son Matthew. Matthew had decided he would rather have a longer skill-based future in machining than he would as an early-career footballer when he played for Birmingham City. Indeed, under his father’s training he progressed to become a director of Davturn, having learnt very quickly to become a skilled programmer and machine setter. The firm also has two apprentices who, like Matthew, are being taught how to competitively apply and use the technology involved in modern machining techniques.
Today Davturn has some 20 active, mostly Midlands-based customers, from sectors that include hydraulics and pneumatics, electrical, door-closure, fastener, construction, vehicle and rail, as well as control cabling. This means the company faces a broad brush of component types from batches of 1000 to almost continuous production of 500,000 with cycle times varying between 15 seconds and 5 minutes. Materials range from plastics to aluminium and high-grade steels.

Since its installation, the BNE-51SY6 has not stopped producing components, with the machine running seven days around-the-clock. During the night and at weekends, machine monitoring creates a call-out in the event of any stoppages to production.
Says Matthew Birley: “The capability of the machine to hold so many tools on the two 12-station, all-driven turrets means we can easily accommodate a suite of common tooling and rarely need to change a tool holder. As a result, resetting is generally prepared and quick; most operations take less than 40 minutes, which helps keep our utilisation of the machine very high.”
He then explains how he uses the latest Citizen Wizard programming aid for both Miyano machines: “This certainly enables new multi-featured parts, often involving difficult materials, to be efficiently programmed with good balance to the cycle between the two spindles.”
Matthew Birley follows on to describe one part produced in a batches of 2000 from 25 mm EN16T bar for use in truck suspensions: “We held 0.025 mm in the bore and 0.02 mm on the outside diameter, which has a 0.8 CLA surface finish without any interruptions for adjustment.”
The part involved all tools being able to be used in overlapping operations between the two spindles and two turrets: “With the power available and the inbuilt rigidity of the machine, it was very straightforward to achieve a balanced machining cycle between each spindle.”
The part involved turning, drilling and counter-boring, the rolling of an M10 internal thread, and the milling of an 18 mm hexagon, which were all completed in a 2 minute cycle.
The Miyano BNE-51SY6 has been developed for single-cycle machining with the ability to cut using three tools that simultaneously overlap when needed at both ends of a workpiece. This capability is supported by the high rigidity of the 7.8 tonne machine, which features box-way slides. The machine has a 15 kW main and 7.5 kW secondary spindle, both having maximum speeds of 5000 rpm, as well as 12-station all-driven turrets.
Having the flexibility of the new BNE has also helped win a contract involving 1000 windscreen wiper assemblies a month for the railway industry. Here a range of component sizes in 303 stainless steel benefitted from balanced machining cycles involving drilling, turning, boring and threading M26x1 each end with 45 mm lengths using both spindles.

“This capability was an important factor in establishing a competitive price to win and succeed in the contact,” says Birley. “Investing in the Miyano, and with the level of support from Citizen’s application team, means we are now riding high.”
He goes on to provide details of a further contract won following the machine installation. This involves a six part series of hydraulic valve sleeves complete with spools between 16 and 30 mm diameter in 440-C stainless steel.
“We are able to machine the largest of these in under 5 minutes, with the most complex having 11 grooves in the outside diameter and 50 holes pitch-drilled 5 mm diameter from the grooves into the bore, which has 0.05 mm tolerance,” he explains. “As we are able to simultaneously combination gang-drill the holes using both turrets and fully deburr in-cycle, we are utilising a totally different capability that we could never even have dreamt about before.”
For further information www.citizenmachinery.co.uk