When Pro-Cut Precision Engineering opened its doors for business just over 10 years ago, the objective was to invest in the very latest equipment to ensure the Milton Keynes business could machine high-quality components in short lead times. As a company that has acquired a multitude of three and five-axis Hurco machine tools for machining complex parts, component programming was becoming a time-consuming process – that was until Pro-Cut invested in the hyperMILL CAM system from Open Mind Technologies.

The subcontract business works across several areas, serving sectors such as motorsport, defence and industrial machinery. Explaining the reasoning behind investing in hyperMILL, Pro-Cut Precision Engineering programmer, Alex Parris-Hammons, says: “We previously had a CAM system, as well as programming many components at the machines, but we were losing time by not being able to stay ahead of the game. hyperMILL allows us to program offline and do all the programming while the machine is cutting a current job. This enables us to build a queue of future jobs.

“We were doing five-axis work with our previous CAM system, but found the collision detection wasn’t great,” continues Parris-Hammons. “In fact, we had to lie to the software system to get the parts we needed. With hyperMILL that isn’t the case; it identifies where the collisions are, both in an internal and external simulation. It provides a list of where the collisions are, and it makes it simple to correct any problems. hyperMILL is known for its collision detection and with that, you can trust the billets going on the machine will come out as 100% correct parts.”

Now with two seats of hyperMILL, Parris-Hammons recalls the initial installation of the system: “The plan was to use it initially for simple components and then build-up to the full capability of hyperMILL, which is five-axis simultaneous tool paths. This would give us better surface finishes and faster machining times. In the early stages, I called the Open Mind technical support team and they were able to walk me through any scenarios by using Team Viewer and a telephone call to resolve any issues.”

Steve Holmes, managing director at Pro-Cut Precision Engineering, takes up the story: “We purchased hyperMILL a little while ago actually, and Alex had done the training, but we naturally kept falling back to our existing CAM provider due to tight deadlines and several other factors. For a little while, hyperMILL was just sitting there, but then this one particular part came along. It was a challenging aluminium electronic casing component that was outside the scope of our current CADCAM system. So, we decided that this was the part that we begin with, where we jump in and manufacture with five-axis simultaneous hyperMILL machining.”

As the programmer tasked with creating the program for the complex aluminium electrical housing part, Parris-Hammons highlights the features that stood out: “The five-axis and the Z-level finishing is very good with this software. We just have to click on a surface, and hyperMILL will machine it. Once you understand how it works, it’s very easy to use and get up to speed. It means we can quickly reach competence levels where we can do complex work much easier.

“The tool library is also very good,” he adds. “It allows you to input a lot of information on each tool and the respective holder. When you put that information into the system to do the simulation, it will then calculate whether it is going to collide with your fixtures or the machine. It will detect and protect itself.”

Taking a closer look at the electrical housing part, Parris-Hammons says: “For the first operation we held the part in a Lang vice, machined the top and all of the internal sections, as well as the outside profiles. This first operation alone required upwards of 25 tools and the hyperMILL tool library keeps that information ready, so we can access it for other upcoming jobs. This makes the whole process of programming a lot quicker and easier.”

Discussing potential collisions and tool path and strategies, he says: “With the tool library we can set up a tool length and how far the tool protrudes from the holder; that data is used when hyperMILL is calculating. This avoids collisions and also tells us how much further the tool needs to stick out to avoid a collision.”

Following the first operation, the aluminium housing was turned over for machining on the opposite face.

“We made a fixture plate to locate on the inside of the component and threaded the tabs to pull down the periphery of the part,” explains Parris-Hammons. “On the second side of the part, we used six tools. Programming the component took a couple of days. However, now that I have undergone this steep learning curve and know what to do, programming similar future components would take significantly less time – we could probably program this part in half a day now.

“Previously, this part would have been very difficult to program without hyperMILL. The second side of the component would have undoubtedly made our previous CAM system crash as there is a lot of information and a lot of code being produced. With hyperMILL, we have machined the complete component in just 15 hours. Now that we have used this very complex part as the first push to get into hyperMILL, we’re very pleased to be using it for all of our parts.”

Concluding on why the company opted for hyperMILL, Holmes says: “Our previous system had its merits, but it didn’t have the process security, collision detection and avoidance, and it would have been incapable of the complex five-axis work that hyperMILL can breeze through. On the shop floor, it’s still early in our learning curve to qualify all the benefits, but we can already see that it’s improving surface finishes. Additionally, when we are rough machining, there is no ‘fresh air cutting’ with hyperMILL – our previous system didn’t have this level of intelligence. hyperMILL really is the next level.”

For further information
www.openmind-tech.com

Established in 1947, MRT Castings specialises in the manufacture of high-quality aluminium die castings. In addition to regularly investing in the most up-to-date casting technologies, the progressive family business has introduced a range of complementary end-to-end services over the past 70 years. Along with state-of-the-art high-pressure and gravity die casting, the Andover-based company now provides tool making, surface finishing, mechanical assembly and, not least, a comprehensive CNC machining provision.

The mainstay of MRT Castings’ impressive machining facility is its collection of Brother CNC vertical machining centres supplied by Whitehouse Machine Tools. MRT’s policy of standardising on machines from a single supplier provides enhanced flexibility, as both operators and products are interchangeable between machines.

Additional benefits include the use of standardised fixtures, tooling and CNC rotary tables.
Having previously used two well-known brands of CNC rotary tables, following advice from Whitehouse Machine Tools, the company’s most recently installed Brother VMCs feature PL Lehmann CNC rotary tables.

MRT Castings’ managing director Phil Rawnson says: “We are able to support our customers from initial ideas, through product development and design for manufacture stages, to full production and logistics. Our extensive in-house CNC machining facilities are at the very core of our operations. To help ensure short lead times and the manufacture of premium quality products we use a range of Brother machine tools, the fastest machining centres available.

“Such is the quality and cost-effective nature of our CNC provision, in addition to machining die castings that are produced in our own foundry, we also machine components cast by other companies,” continues Rawnson. “As we usually perform small-to-medium production runs on a diverse range of products, we need each of our machine tools to deliver the best possible levels of flexibility, while also striving to maximise machine utilisation times and minimise set-up times. Over several years, our use of rotary tables has made important contributions in these areas.”

As many of the components manufactured at MRT Castings are relatively complex, without the use of rotary tables the company would need to perform two or three different machining operations, rather than producing parts in one hit. The ability to finish components in a single cycle means that MRT does not face the issues related to the accurate relocation of workpieces for subsequent machining operations.

“Over the past 12 months we’ve been involved in the casting and machining of critical parts that were urgently needed for medical ventilators,” explains Rawnson. “To help keep pace with this challenging production schedule we brought the planned purchase of six Brother vertical machining centres forward, bringing our current Brother VMC count up to 25 machines. To provide highly efficient four-axis capabilities, each of our latest six Brother VMCs feature rotary tables from PL Lehmann, which has provided us with a range of advantages.

He adds: “Despite our Lehmann CNC rotary tables being extremely robust and able to perform all the tasks we require, when compared with our previous rotary tables they are relatively small. Their reduced footprints mean that, when mounted inside our Brother VMCs, they take-up minimal area. In addition to releasing machine bed space for other work holding, the reduced size of Lehmann CNC rotary tables means that, when they are not required, they can often remain inside our VMCs while other machining operations take place. Additionally, the reduced height of Lehmann CNC rotary tables helps to increase the available working volume of our machines.

“As well as benefiting from the quality of Lehmann’s products, we received excellent installation and interface help from Whitehouse Machine Tools and PL Lehmann’s UK service agent. The machining flexibility, precision and speed delivered by our Lehmann rotary tables is now proving invaluable to MRT Castings.”

PL Lehmann has been involved in the design and manufacture of high-quality rotary tables for over four decades. The in-depth expertise gained throughout this time is reflected in the quality of the company’s products. To help reduce parts and enable the availability of Swiss quality at a cost-effective price, Lehmann rotary tables are based on a novel modular design system. This highly efficient arrangement enables the availability of a wide range of CNC rotary table options to meet customer needs.

Four sizes of Lehmann CNC rotary tables are available – 507, 510, 520 and 530 mm – with centre heights from 110 to 240 mm. Due to the company’s modular design approach, from these size options it is possible to offer more than 170 different rotary table variants. Models are available from basic single-spindle 4th axis units, to four-spindle tilting rotary tables with 4th and 5th axis capabilities. Now, rather than compromise and obtain a rotary table that represents a close match to a machining requirement, Lehmann customers are able to take delivery of a high-quality CNC rotary table that corresponds exactly to their specific needs.

In addition, the company’s modular design system means that the purchase of a well-engineered Lehmann CNC rotary table represents a safe, future-proof investment. For example, if a customer’s manufacturing requirements change, instead of investing in a new rotary table, the existing Lehmann CNC unit can be easily modified and adapted to changes in use.

Lehmann’s standardised spindle arrangement allows the use of an extremely wide range of workpiece clamping systems. As a result, in addition to standard work holding being set-up for an initial workpiece range, the system can quickly convert to accommodate other workpieces.

PL Lehmann says that its heavy-duty CNC rotary tables have earned a global reputation for performance, quality and longevity. Further aiding efficient, precision machining, the company’s robust products benefit from high clamping torque, load weight capabilities and accuracy specifications.

For further information
www.lehmann-rotary-tables.com

As an engineering solutions company, A&M EDM is always striving to enhance its operations and capabilities to maximise its service to clients in the aerospace, motorsport, automotive, marine, medical, rail, defence and general subcontract sectors. To achieve this, the company has invested in technology that extends from three, four and five-axis machining centres, EDM wire and spark erosion, and laser welding, through to a temperature-controlled metrology department. When A&M EDM was not getting the best from its machines and cutting tools, the company worked with MSC Industrial Supply to instigate a change of cutting fluid supply. The result was a relationship with the cutting fluid experts at Rocol.

Playing a proud role in the Ventilator Challenge and having more than 57 CNC machines on the shop floor, as well as a host of accreditations and accolades, the Smethwick-based manufacturer utilises MSC to deliver best practice engineering support. Frequent onsite visits proactively identify ways to help A&M EDM optimise its processes. When it came to improving the performance of its metalworking fluids while maintaining high-quality machining, MSC identified Rocol as the perfect partner to collaborate with A&M EDM.

Like many subcontract manufacturers, A&M EDM machines a variety of materials that include stainless steel, mild steel, aluminium, Inconel, titanium and exotics with a variety of production demands from bespoke one-offs and short runs through to longer run batches.

This variety of materials poses a challenge for any cutting fluid supplier, but Rocol recommended its Ultracut Evo 255 metalworking coolant, an extreme pressure (EP) soluble oil-water mix cutting fluid. Rocol and MSC suggested this product as it is not only versatile and suitable for a wide variety of machining applications and materials, but would deliver a significant saving in the volume of coolant required.

When asked why the company changed cutting fluid supplier to Rocol, Gary Surman from A&M EDM says: “We had three fundamental issues. Firstly, we had operators who were complaining about irritated skin. There was also a smell in the workshop, while thirdly our tool life seemed to be diminishing relatively quickly.”

Adds Surman: “We are delighted that MSC and Rocol have come in and analysed our coolant consumption and recommended a solution that will reduce this to half the amount we were using previously. They invested time in understanding our objectives, and demonstrated a commitment and determination to help us achieve them. We look forward to an ongoing relationship where MSC and Rocol will continue to assess and benchmark our machines regularly, helping us to achieve further efficiency and productivity gains.”

Rocol analysed A&M EDM’s coolant consumption, accounting for the materials and applications while taking samples from active machining operations. The tests at Rocol’s laboratory delivered a comprehensive report on the current fluid product, with details such as the wear ratio, dilution and consumption. From the analysis it was possible to conclude that coolant usage was much higher than it should be, and that A&M EDM needed a versatile, high-performance cutting fluid that would deliver consistent usage and quality results on a range of different materials.

Commenting on the Ultracut Evo 255 Surman says: “Once we got the product into the machines, we had no further concerns about skin irritation, the smell had dissipated and tool life improved.”

Machine operator Callum Bowen re-iterates the point on odour, stating: “The Rocol coolant has made a difference. When I get home from work, I no longer smell; it doesn’t stick to my clothes, unlike the previous product we were using. Additionally, the fluid is very good when cutting different types of material, and it does not fog-up the glass screen on the machine doors, so we can see what’s going on.”

The Rocol Ultracut Evo range of operator-friendly, water-soluble cutting fluids is inherently resistant to degradation and contains no biocides or skin sensitisers. These attributes demonstrate low foaming qualities and reject tramp oil to provide excellent cutting performance and residual corrosion protection.

“Our operators have had no noticeable effect on their hands, whereas before they were getting skin irritation,” says Surman. “Even looking inside the machines, they are much cleaner than they were previously, and we can only put that down to the old coolant congealing and sticking to the walls and surfaces of the machine.”

The analysis showed that with Rocol Ultracut Evo 255, dilution levels improved from 19:1 to 40:1, reducing A&M EDM’s consumption from 41,000 litres to just 20,048 litres per annum. The reduced consumption rate outweighed the increased cost per unit, resulting in a cost saving of £16,900 per year.

“We used to buy around 10 IBCs every year and we are now down to five,” says Surman. “However, it’s not just the cost of coolant we are measuring here. There has also been a significant drop in the costs of our cutters, which we can only put down to the cutting fluid and EP additives that are allowing the tools to last longer. We’ve had a 40% reduction in our tooling spend where roughing operations were being carried out.”

Referring to the waste management of cutting fluid, Surman says: “When the suds kept going-off, we had to dispose of it under our ISO14001 environmental standard. Now, we are no longer disposing of 10 to 15,000 litres a year due to coolant that has perished.”
Naturally, Surman is pleased with the service provided by MSC and Rocol: “Initially, when we were doing the changeover, Rocol engineers were here every day. They were monitoring and checking vigorously. Now, with the coolant fully implemented, they visit once a month. They come round and do all the checks, the reports and the laboratory testing. If we have a problem, Rocol is only a phone call away and they will pop-in on the same afternoon or the following day.”

With a vast machine shop, Surman comments on the implementation throughout the facility: “We had our maintenance engineer fit an IBC and pipe it into every machine, so we have one source with hoses connected to every machining resource. We now have no spillages on the shop floor and we’re no longer trying to carry tanks around.

“The ease of changeover from the previous cutting fluid to Rocol was simple,” he continues. “Rocol did all of the laboratory work in the background. They came in, investigated our work and found a product that was compatible with the materials and jobs we were machining, so we were able to mix. We didn’t need to empty the sumps, we just added it to what was already there, and over time we are now fully Evo 255 compliant.”

For further information
www.rocol.com

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has recently supplied Coventry-based precision machining specialist, MNB Precision, with a large-capacity Doosan SMX 3100 multi-tasking machine and a Doosan DNM 6700 vertical machining centre. Installed at MNB’s 36,000 sq ft facility in May 2021, the machines’ arrival forms part of a larger technology investment package that, over the next seven months, will see MNB take ownership of four more Doosan machines (two lathes, a vertical machining centre and a mill-turn machine). By the end of the year, MNB will have 20 Doosan machines at its disposal, representing a sizeable proportion of the company’s 55 total machine tool resource.

Says commercial director Elliot Benton: “We are committed to continuous improvement and, as such, are no strangers to making strategic and prudent investments in advanced manufacturing and machining technologies. The sectors where we operate are ultra-competitive and the investments we make are intended to help us improve quality, productivity and operational efficiencies.”

Doosan’s SMX 3100 is a high-productivity multi-tasking machine equipped with a 12” chuck, a 30 kW/4000 rpm spindle, a B-axis milling spindle, a 40-tool magazine, a servo-driven tailstock, linear scales and the latest FANUC 31iB5 control. As part of the investment, Mills supplied the machine with an SLU-X4 steady rest, which in conjunction with the tailstock, enables the reliable and high-accuracy machining of long workpieces.

The SMX 3100 is the first Doosan turn-mill machine acquired by MNB, but the company is no stranger to the technology itself.

“Turn-mill technology enables us to machine complex, high-precision parts in one hit,” says Benton. “The technology can make jobs previously considered unprofitable, a more attractive proposition and helps significantly reduce job set-up and part cycle times. The investment in the SMX 3100 comes specifically from the need to machine high-precision oil and gas plug-type components. Manufactured from low-alloy steel, the parts are required in large volumes for a customer in Norway.

“The SMX 3100 is a powerful, flexible and accurate turn-mill machine,” states Benton. “The price and performance of the machine, its reputation in the market and the fact that it’s backed by Mills CNC’s aftersales service and support, made the investment decision a relatively straightforward one to make.”

Doosan’s DNM 6700 is a large-capacity vertical machining centre equipped with a 12,000 rpm directly-coupled spindle, a 30-position ATC, roller LM guideways, thermal compensation systems, and the latest Fanuc 0iMP control with the advanced iHMI touchscreen. To increase productivity and ensure machining flexibility, Mills supplied the DNM 6700 with an integrated four-/five-axis rotary table.

Says Benton: “We invested in a Doosan DNM 5700 vertical machining centre in 2017 and can vouch for the machine’s accuracy, speed and reliability. Our latest DNM 6700 provides us with a larger travels [1300 x 670 x 625 mm] and a bigger work table [1500 x 670 mm]. The DNM 6700 increases the machining capacity of i8 Ltd, a new, precision engineering subsidiary we created and absorbed into MNB in 2019 following the purchase of the assets of Integr8, a local engineering subcontractor. The machine was acquired to machine complex parts for a water treatment customer.”

MNB Precision and Mills CNC have a partnership that dates back to 2012 when the former invested in its first Doosan machine, a large-capacity Puma 800XL lathe. Since then MNB has regularly invested in Doosan lathes and machining centres from Mills.

“Doosan machine tools deliver best-in-class performance,” says Benton. “They are reliable and competitively priced.”

Established over 40 years ago MNB Precision, a family-owned business, is a provider of manufacturing and precision engineering services to a growing number of OEM and tier-one companies operating primarily, but not exclusively, in the oil and gas sector. Other industry sectors served by MNB Precision include power generation, rail, defence, nuclear and automotive.

The company manufactures a range of different-sized components, from handheld parts up to others that measure 11 m in length and 1 m in diameter, weighing up to 8 tonnes.

In addition to CNC turning and milling, MNB provides other in-house machining services that include jig boring, grinding and EDM. The company has impressive testing and inspection capabilities located in a temperature controlled environment and, to further differentiate itself in the market, offers customers a range of secondary services that include shot peening, NDT, magnetic particle inspection and liquid dye penetration. In the near future, MNB is considering further augmenting its services by opening up separate materials and surface treatment divisions.

Serving the oil and gas sector for four decades has meant that the company has experienced and survived a number of industry downturns. In response to the sector’s perennial volatility and to enable the company to have more control over its own destiny, MNB’s current leadership team has, over recent years, implemented a number of innovative and interrelated business strategies.

The company’s strategies are working. Sales turnover, prior to the pandemic, increased from £3.3m in 2016/17 to £20m in 2019/20. Such outstanding sales success has not gone unnoticed, with the company earning a number of recent and well-deserved accolades and awards. For instance, in 2020, MNB appeared 30th in the Sunday Times Virgin Atlantic Fast Track 100 league table of UK companies with the fastest-growing sales.

MNB’s recently introduced business strategies, across all of its operations, have been transformative. These include the adoption of a ‘servitisation’ business model, proactive and aggressive sales, and diversification.

In summary, MNB Precision is clearly a manufacturing company that thinks outside, and inside, the box.

Recent and future investment in advanced machine tool technologies combined with its servitisation business approach has helped, and will help, the company compete and win more work in the oil and gas sector which, independent forecasters have predicted will bounce back strongly in the second half of 2021.

MNB’s more proactive and targeted sales strategies are driving demand for its services, and the creation of a manufacturing facility in Saudi Arabia will put the company in the box seat in one of its primary markets. Furthermore, MNB’s move into other sectors and the recent creation of i8 Ltd, are further evidence of its forward-looking and focused business approach.

All three strategies rely on MNB having access to class-leading, high-performance machine tools, which is why the company continues to invest in Doosan machines from Mills CNC.

For further information
www.millscnc.co.uk

At the Barnstaple subcontract machining facility of Witon Engineering, the turn-milling of relatively complex components from 16 mm diameter bar previously took place on 32 mm capacity sliding-head lathes, rather than smaller capacity models, to take advantage of the extra CNC axes and tools available on the larger machines. The company has now transferred this type of work to a more nimble, 25 mm bar capacity Citizen Cincom D25-VIIILFV sliding-head turning centre, installed in January 2021. The first two jobs have shown cycle time reductions of 20% or more.

Since the mid-90s, Witon Engineering has bought 17 bar-fed lathes from Citizen Machinery, of which one was a 42 mm bar capacity Miyano fixed-head machine, the others being various Cincom sliding-head models for turning up to 32 mm stock. There are currently 11 Citizen machines on the shop floor, following the replacement of earlier models over the years. Lathes from this supplier therefore account for approaching half of the 25 of bar autos in the factory, comprising 13 sliding-head models, eight single-spindle fixed-head turning centres and four CNC multi-spindle automatics.

The first component transferred to the D25 was an EN1A steel shaft for a lawnmower. Previously, the machining of this part took place on an L32-VII, of which there are three on site. As 180,000 have to be produced to fulfil the current contract, the 20% cycle time reduction leads to a significant production cost saving.

Another component benefiting from machining on the D25 is a 304 stainless steel fuel inlet fitting for an automotive customer. It used to be turn-milled on a pair of Cincom M32s in a cycle time of 72 seconds, but this has been cut to 53 seconds, representing a 26% saving. With 55,000-off needed, the economy gained is significant.

Ian Clapp, workshop manager at the Barnstaple factory, says: “We operate a couple of 20 mm capacity, dual-platen sliders of another make and knew this configuration offered quick cycle times. However, we saw what our long-standing sliding-head lathe supplier Citizen was offering in the D25, a machine with larger bar capacity plus the ability to carry out work up to 32 mm diameter without the guide bush for more economical material usage when producing shorter components. The model also has the benefit of a programmable B axis, so we decided to go for this option.”

Notably, the gang tool platens are in front of and behind the spindle centreline, with Z-axis motion provided on the rear carrier to allow balanced turning, milling or drilling, or simultaneous rough and finish turning. The B axis on the front post, carrying up to four driven tools on either side to service either the main or counter spindle, swivels by up to 135°. A further feature of the lathe is the potential to control three axis groups simultaneously via the Mitsubishi 800 CNC system (so three tools can be in cut at the same time).

Another benefit of this 12-axis CNC turn-mill centre is that it incorporates Citizen’s programmable LFV (low frequency vibration) chip-breaking technology in the control. LFV automatically breaks into smaller pieces the long, stringy swarf produced when machining materials such as copper, plastics and high alloy steels. Bird-nesting around the tool and component – and the consequent damage – is therefore avoided. Although LFV cycles have not been included in programs run so far on the D25 at Barnstaple, it is nevertheless there to use when appropriate jobs come along.

Witon Engineering underwent a change of management at the end of 2016 when second-generation owner and managing director Ian Sheldon retired. The firm is now run by Ian’s son-in-law Tom Courtney, who is general manager, alongside Sheldon’s daughters, Hayley Neate and Gemma Courtney, who are both directors. Operations still predominantly centre on precision turned parts production using CNC lathes, the cam multi-spindle auto shop having closed in 2018. Two three-axis, vertical-spindle machining centres are also in use.

Large batch runs are the norm: Witon Engineering produces one electrical connector part at a rate of 100,000 per month, and even one of the machining centres is currently completing a contract for 500,000-off prismatic components.

Says Neate: “We are keeping Witon Engineering basically on the same trajectory, with the accent on turning and long periods of unattended running during the day through to the end of a twilight shift finishing at 00:30 every weekday.

“The onset of the pandemic reduced business early on, especially as work for the automotive sector, traditionally a large proportion of our business, was badly affected,” she continues. “However, we have gained extra contracts in other sectors to compensate, such as parts for lubrication systems and household goods. When the automotive work returns, our production throughput will be at a record high and we will carry on investing in top quality plant like Citizen lathes to meet demand.”

For further information
www.citizenmachinery.co.uk