Tripartite collaboration between project enabler/integrator, machine tool supplier and tool-holding specialist is continually pushing the boundaries of high-performance machining and increasingly reducing machining lead times and production costs for a major aerospace company.

The ongoing work between the project lead – the University of Sheffield Advanced Manufacturing Research Centre (AMRC) – and machine tool specialist Starrag UK, plus the tooling expertise of Nikken Kosakusho on a variety of aluminium and titanium aerostructure workpieces is cutting piece part costs through the creation of improved machining routines.

“Although not directly targeted by the projects, in some cases reductions in cycle times are a rewarding by-product of the work; in certain instances of more than 50% compared with ‘conventional’ machining processes,” says Starrag UK’s director for sales and applications, Lee Scott.

Among Nikken’s tool-holding solutions is the Slim Chuck, a high-accuracy collet chuck that boasts minimal runout – 3 µm at 4xD– leading to higher component precision and improved tool life. Also, its maximum gripping torque of more than double that of traditional ER alternatives, not only complements the Heckert X40’s rigidity/stability to permit more aggressive machining parameters, it also improves process security and therefore leads to reduced scrap.

The workpieces – of titanium and aluminium – all fit within the machining envelope of 700 x 750 x 750 mm.

Tom McCready, engineering and operations manager at the AMRC’s Machining Group, says: “With all three partners collaborating closely, we have so far collectively achieved some incredibly successful results by pushing the limits of the machine and the tooling for increased metal removal, without jeopardising quality, on these workpieces.”
For further information www.starrag.com

Established at the dawn of the millennium, Oberon Performance has gained a global reputation for the premium quality of its range of motorcycle accessories, which include adjustable levers, billet headlights, brake and clutch lever protectors, clutch slave cylinders, mirror extenders, foot-peg kits, and handlebar risers.

To ensure that the company’s busy Haas multi-axis CNC milling machine was able to reach its full productive potential and keep pace with demand, Oberon Performance director Steve Evans recently investigated machine tool automation aids. Having compared the products of several leading providers, the company purchased a Robo-Trex automation system from Lang Technik UK.

“When compared with the new machine tool we contemplated, our recently installed Lang system occupies a much smaller footprint,” says Evans. “Furthermore, it cost a fraction of the price and it has helped us to achieve the same increase in production as the new machine would have.”

He adds: “Operating unattended and fed by the Lang Robo-Trex system, our Haas machine now runs unattended through each shift. Then, when required, at the end of a working day, we’re able to restock our Robo-Trex trollies with batches of workpiece blanks, allowing the machine to maintain unmanned production in lights-out mode through the night.

The Lang Robo-Trex robot system uses two high-capacity trollies that act as mobile storage mediums for multiple Lang vices which hold workpiece blanks. Notably, the system’s operation is logical and trouble-free: a robot picks a vice from the trolley, loads it into the machine tool and,once machining is complete, returns the vice holding the completed component to the trolley. When filled with fully machined parts, the trolley is removed and a replacement loaded with ready-to-machine workpiece blanks is added.
For further information www.lang-technik.co.uk