Connector parts are produced within tolerance and at lower cost on a CNC sliding head automatic and economical batch sizes are 200-off and less.
A recent convert to CNC sliding-head mill-turning, Hampshire, UK subcontractor Croft Engineering supplies a local electronic equipment manufacturer with connector parts that were previously produced by another contract machinist in the UK to a lower standard on cam automatics. For years the customer thought that the poor quality was normal; then it approached a subcontractor in India to try to obtain a better price and was disappointed at the quality of the samples that came back. The parts are now produced within tolerance and at lower cost on Croft's multi-axis Star SR-32J sliding head automatic lathe, according to Jason Mortara, joint owner of Croft with his parents, Paul and Judy.
Furthermore, economic batch size is down to 200-off or less and delivery is fast, factors that are of considerable benefit to the customer, as it specialises in bespoke electronic instruments for niche markets.
The arrangement has worked so well that in the first seven months, over 50 different styles and sizes of connector from 6 to 16mm diameter and up to 30mm long had been produced on the Star.
What was originally envisaged as GBP 15,000 of business annually will in the 12 months to March 2007 be at least double that figure.
So pleased is the customer that its proprietor has written a letter to Mortara stating, 'The improved quality and delivery times from Croft, together with keener prices, have enabled us to give a better service to our existing clients and to gain new business from our competitors.' Croft found that there was little money to be made using its manually operated machine tools, so a few years ago the company invested in a CNC chucking lathe and milling machine.
However, staff costs were high because most parts still needed subsequent operations, and overheads such as rates and electricity were climbing.
Competition was fierce and profit margins remained slim.
It became obvious that a change of direction was needed.
Enquiries were being received for components that were more suitable for sliding-head machining.
So a study was carried out which showed that the best lathe for the type of work under discussion was the Star SR-32J.
An investment of over GBP 100,000 in a machine tool is a big step for a family-owned company, but Croft was getting all the right signals from potential customers, such as the electronic equipment manufacturer which happened to call in for a simple manual job to be done, and a press shop in Oxford that needed low cost, threaded inserts in quantities of 4,000-off.
Discussions with these two prospects, coupled with on-going machining of concrete drill adapter components up to 32mm diameter for another party, eventually persuaded Croft to take the plunge.
A second-hand sliding head machine was rejected, as Croft was new to the technology and needed the reassurance of having a comprehensive service package including warranty, cycle time estimates, programs, training, tooling advice and telephone helpdesk.
'All have been readily forthcoming from Star GB,' said Paul Mortara.
'It has been a very good experience.
We were comfortable with the Star lathe, Fanuc control and FMB bar magazine three months after installation - earlier than we thought.' He added: 'Star even recommended the finance house, which was able to offer good terms as it is familiar with the higher-than-average residual value of the machines.' Since the SR-32J was installed in March 2006, the situation at Croft Engineering has been transformed.
Few subcontractors in the area have such a capable mill-turning facility, so competition is much less.
Once set, the bar-fed machine works around the clock with minimal attendance during the day and unmanned overnight, turning out top quality components.
Paul Mortara sums up the advantage of the SR-32J using the example of the concrete adapter parts that the firm has been making since 1993.
Initially the components were machined entirely manually; then using the CNC chucker followed by manual drilling, tapping and hexagon milling on three separate machines; and finally in automatic, 'one-hit' cycles on the Star.
Where it used to take approximately 40h to machine a batch of 500-off, it now takes a third of the time with very little manual intervention, added to which quality is greatly improved.
Full use is made of the SR-32J's capabilities.
Tolerances within 10 micron are routinely held, whereas that was far more difficult on Croft's other production plant.
All parts are transferred to the opposed sub spindle for reverse endworking and around half undergo driven tool operations.
Of the other 50% of components, some can be extremely simple, prompting people to suggest one does not need a CNC slider to produce them.
Croft's experience is that these are machined just as cost effectively as more complex parts.
Jason cited the example of valve guides they produce in various sizes for classic cars.
Each guide requires only a short cycle, but all are very price-sensitive.
The job was referred from another subcontractor that was unable to be competitive.
Croft's view is that even if a majority of work is relatively simple and only the occasional part requires a complicated machining sequence, there is no problem justifying the purchase of a CNC sliding head automatic.
Unit production cost will always be an issue for customers, yet a subcontractor must be able to amortise a machine tool over a reasonable period.
One method that Croft uses to assist in meeting these conflicting needs is to suggest to a customer that design changes are made to a component so that it can be produced in a shorter cycle time on the Star, and perhaps in one operation rather than in two or three.
Another cost-down technique is to offer to fulfill a non-urgent order during the following week, say, when the correct size and type of bar is scheduled to be in the magazine.
This saves set-up time and reduces the price per part.
Paul Mortara concluded by commenting, 'Manufacturers in the UK often do not want to have their components made abroad, but feel that they are forced to by customers demanding ever lower prices.
Now there is another option to consider.' He said: 'Highly automated, multi-tasking machine tools like the Star are the answer to keeping work in Britain.
We will probably buy a 16mm or 20mm model next, which will be even more economical at producing smaller parts and increase our competitiveness further.'
Tuesday, March 27, 2007
Powered spindles and complex machining
The MultiAlpha 8x20 and 6x32 machines with their powered spindles and complex reverse face machining capability are well suited to machining complex components in a single operation.
The ongoing product implementation strategy for multi-spindle turning units at Tornos is progressing in giant steps. The recently launched MultiAlpha 8x20 and 6x32 machines with their powered spindles and complex reverse face machining capability are well suited to machining complex components right through to completion in a single operation. To enhance this capability even further, four additional units are being fitted to the new machines with immediate effect.
The first of the new innovations is the Y axis on the slide-rest.
This is an ideal addition for manufacturing complex components as it simplifies challenging operations such as offset transverse bores, the milling of surfaces with transit functions, the milling of slots and the deburring of transverse bores.
An extensive and diverse range of macros are provided to make these functions easy to program, giving the end user the immediate benefits.
The Y-axis on the slide rest has a 12mm stroke with a torque of 1.5Nm delivering a maximum speed of 8,000rpm.
For customers requiring more speed, a 0.75Nm unit is available to deliver 16,000rpm with gearboxes being readily available to enhance spindle speeds further.
The Y axis frontal unit is an option that exists in two versions - one as a driven unit and the other one not driven.
The non-driven unit is used primarily for internal machining.
This makes it possible to perform processing steps directly from the front, which were previously carried out using the slide-rest.
This leaves the slide-rest free to perform other machining operations simultaneously.
Here too, macros can be employed for operations such as internal thread whirling to simplify the task.
The second variant takes the form of a frontal Y axis with drive unit.
Complex components frequently require several drilling operations from the front with relatively narrow diameters.
This equipment is ideally suited to this purpose.
Thanks to the powered spindles, bar stock can be positioned virtually anywhere.
This unit, like the Y axis on the slide rest has 1.5Nm of torque with a maximum speed of 8,000rpm with the option of a 0.75Nm unit with a maximum speed of 16,000rpm.
The new transverse drilling unit is proving to be the icing on the cake for Tornos customers.
It is a small and powerful unit that can be fitted in any position without problem thanks to its intelligent symmetrical design.
This equipment can be retrofitted to existing MultiDECO units as well as the new MultiAlpha 8x20 and 6x32.
The modularity of this unit is further enhanced by equipping it with a diverse range of heads, either in the form of a direct drilling unit or with a 90 degree head for performing lateral drilling/milling operations.
The drill has 2Nm of Torque with a maximum speed of 8,000rpm, however there is the option of a gearbox that will provide a torque output of 10Nm with a maximum speed of 1,250rpm.
With these standard items of equipment, Tornos is consistently striving to enhance its multi-spindle product strategy, enabling complex components to be machined through to completion in a single fixture setting.
The ongoing product implementation strategy for multi-spindle turning units at Tornos is progressing in giant steps. The recently launched MultiAlpha 8x20 and 6x32 machines with their powered spindles and complex reverse face machining capability are well suited to machining complex components right through to completion in a single operation. To enhance this capability even further, four additional units are being fitted to the new machines with immediate effect.
The first of the new innovations is the Y axis on the slide-rest.
This is an ideal addition for manufacturing complex components as it simplifies challenging operations such as offset transverse bores, the milling of surfaces with transit functions, the milling of slots and the deburring of transverse bores.
An extensive and diverse range of macros are provided to make these functions easy to program, giving the end user the immediate benefits.
The Y-axis on the slide rest has a 12mm stroke with a torque of 1.5Nm delivering a maximum speed of 8,000rpm.
For customers requiring more speed, a 0.75Nm unit is available to deliver 16,000rpm with gearboxes being readily available to enhance spindle speeds further.
The Y axis frontal unit is an option that exists in two versions - one as a driven unit and the other one not driven.
The non-driven unit is used primarily for internal machining.
This makes it possible to perform processing steps directly from the front, which were previously carried out using the slide-rest.
This leaves the slide-rest free to perform other machining operations simultaneously.
Here too, macros can be employed for operations such as internal thread whirling to simplify the task.
The second variant takes the form of a frontal Y axis with drive unit.
Complex components frequently require several drilling operations from the front with relatively narrow diameters.
This equipment is ideally suited to this purpose.
Thanks to the powered spindles, bar stock can be positioned virtually anywhere.
This unit, like the Y axis on the slide rest has 1.5Nm of torque with a maximum speed of 8,000rpm with the option of a 0.75Nm unit with a maximum speed of 16,000rpm.
The new transverse drilling unit is proving to be the icing on the cake for Tornos customers.
It is a small and powerful unit that can be fitted in any position without problem thanks to its intelligent symmetrical design.
This equipment can be retrofitted to existing MultiDECO units as well as the new MultiAlpha 8x20 and 6x32.
The modularity of this unit is further enhanced by equipping it with a diverse range of heads, either in the form of a direct drilling unit or with a 90 degree head for performing lateral drilling/milling operations.
The drill has 2Nm of Torque with a maximum speed of 8,000rpm, however there is the option of a gearbox that will provide a torque output of 10Nm with a maximum speed of 1,250rpm.
With these standard items of equipment, Tornos is consistently striving to enhance its multi-spindle product strategy, enabling complex components to be machined through to completion in a single fixture setting.
CNC 8mm bar automatic lathe has live tools
An 8mm capacity, single spindle, CNC automatic lathe now has a motorised unit to power live tooling and there is also an option of a workpiece conveyor with the machine.
The world's first 8mm capacity single-spindle, automatic lathe with tailstock - the Deco Sigma 8 (Previously Deco 8sp) from Tornos has undergone product enhancements. Since its launch in 2005, the highly successful Deco Sigma 8 with five basic linear axes now incorporates a motorised unit for live rotary tools and a workpiece conveyor belt to deliver additional productivity options for customers. The new motorised unit enables the user to install a front-mounted and a rear-mounted live rotary tool for simultaneous main and counterspindle operations respectively.
This allows customers to conduct drilling, face milling on or off axis, tangential milling on the diameter with polygon cutting, thread whirling and thread milling currently being researched.
This development brings significantly improved capability to the Deco Sigma 8 allowing customers to achieve relatively complex component manufacture without the cost of a high specification machine.
This development enables the workpiece to be machined on its front and rear faces within compact dimensions whilst retaining every tool position.
It also allows rotational speeds to be set digitally as it is powered by the same S11 motor used to drive transverse spindles.
This new development has a maximum rotational speed of 10,000 rev/min and is suited to ER8 collets with a maximum 5mm tool shank diameter.
The unit can be mounted right at the back of the tool system X1/Y1 and can replace the 'L-shaped' tool support for 2 x 4 fixed turning tools (front and back).
Whenever this equipment is being employed, an 'L-shaped' bracket can be mounted to hold 6 fixed-position axial tools, three at the front and three at the back.
* conveyor system - the Deco Sigma 8 developed from extensive market research enables Tornos to address markets such as the electronics and medical.
The second development, the workpiece conveyor belt lends itself to these specific sectors and enables customers to enhance productivity and simplifies post operation handling of components.
This option enables workpieces to be conveyed from the workpiece separating unit, which is located outside the machine.
The machined workpieces are collected in a perforated tray and when another sorting system is used such as a turntable or a bucket distributor, a workpiece slide can be mounted in place of the tray.
The conveyor belt enables the end user to remove workpieces safely with a conveyor belt speed that can be adjusted to suit the work cycle.
The belt feed rate is fully adjustable and can operate from 1.2 to 21m/min.
This unit can be adapted to work with the customer's choice of external workpiece retrieval and sorting system, making it a truly universal system.
The world's first 8mm capacity single-spindle, automatic lathe with tailstock - the Deco Sigma 8 (Previously Deco 8sp) from Tornos has undergone product enhancements. Since its launch in 2005, the highly successful Deco Sigma 8 with five basic linear axes now incorporates a motorised unit for live rotary tools and a workpiece conveyor belt to deliver additional productivity options for customers. The new motorised unit enables the user to install a front-mounted and a rear-mounted live rotary tool for simultaneous main and counterspindle operations respectively.
This allows customers to conduct drilling, face milling on or off axis, tangential milling on the diameter with polygon cutting, thread whirling and thread milling currently being researched.
This development brings significantly improved capability to the Deco Sigma 8 allowing customers to achieve relatively complex component manufacture without the cost of a high specification machine.
This development enables the workpiece to be machined on its front and rear faces within compact dimensions whilst retaining every tool position.
It also allows rotational speeds to be set digitally as it is powered by the same S11 motor used to drive transverse spindles.
This new development has a maximum rotational speed of 10,000 rev/min and is suited to ER8 collets with a maximum 5mm tool shank diameter.
The unit can be mounted right at the back of the tool system X1/Y1 and can replace the 'L-shaped' tool support for 2 x 4 fixed turning tools (front and back).
Whenever this equipment is being employed, an 'L-shaped' bracket can be mounted to hold 6 fixed-position axial tools, three at the front and three at the back.
* conveyor system - the Deco Sigma 8 developed from extensive market research enables Tornos to address markets such as the electronics and medical.
The second development, the workpiece conveyor belt lends itself to these specific sectors and enables customers to enhance productivity and simplifies post operation handling of components.
This option enables workpieces to be conveyed from the workpiece separating unit, which is located outside the machine.
The machined workpieces are collected in a perforated tray and when another sorting system is used such as a turntable or a bucket distributor, a workpiece slide can be mounted in place of the tray.
The conveyor belt enables the end user to remove workpieces safely with a conveyor belt speed that can be adjusted to suit the work cycle.
The belt feed rate is fully adjustable and can operate from 1.2 to 21m/min.
This unit can be adapted to work with the customer's choice of external workpiece retrieval and sorting system, making it a truly universal system.
CNC automatics replace cam-driven lathes
Replacing cam-driven automatic lathes with CNC sliding head automatic lathes means a couplings maker can benefit on delivery and price and run machines 'lights out'.
The replacement of cam-driven turning with high-technology citizen cnc mill/turning machines has given John Elliot, the 83-year-old managing director of Quality Couplings, a new lease of life. 'The new machines have transformed the company,' he said, 'Giving me completely renewed interest - you could say I've developed a totally new outlook on life.' Following the installation of two Citizen C-Series CNC sliding head automatic lathes Elliot reflected: 'One immediate benefit of CNC technology is that we know exactly where we are with production, quality, delivery and price, and the company is already benefiting from reduced cost of production per part as the new machines are run unmanned at night.' That's a 'far cry' from the situation 12 months ago when he was facing the spectre of a future lack of skills for his traditionally bread-winning, but ageing, cam-driven machine based turning operation as four of his key autosetters (with 75 years service between them) look forward to retirement next year. He decided then it was time for a change and to adopt high technology mill/turning.
After spending some time looking at the leading CNC sliding head machines on the market, he decided in 2005 to buy the two Citizen C-Series machines from NC Engineering in Watford, UK.
These were installed in a refurbished factory unit just four units away from his cam machine shop and arrangements were made for NC Engineering to retrain an autosetter, Dave Reynolds, (who can tell the tales of some 50 years of being around automatic lathes) while 26-year-old CNC setter/operator, Paul Holliman, was recruited to run the new Citizen C16-VII and C32-VIII machines.
Born in 1923, Elliot left school at 14 to serve a seven-year apprenticeship as a pattern maker, followed by several years in the Merchant Navy during the war.
When he was 58, he bought Quality Couplings from The Receiver - at a time when many would rather be thinking of retirement rather than building a business - and moved the company from Birmingham to its current base in High Wycombe, Buckinghamshire.
He set about using traditional cam autos to produce turned parts for pipe fittings, and over the years progressively built a very successful business.
Today, he runs the two machine shops from an office on the shopfloor.
He wakes at 5 am every morning, arrives at work by 7 am and most evenings leaves at 4.45 pm on the dot.
In March next year, he is due to be featured in a Channel 4 television documentary.
Quality Couplings has a customer base of some 600 clients spanning heating and ventilation, gas burner, valves, pipe and hose fittings, pneumatics, heating, hydraulics and automotive suppliers, and it manufactures batches ranging from 500 to 10,000 parts.
CNC machining now takes priority at the firm ('Once established with the Citizens we despatched 11 cam machines to a company in Birmingham,' he said) though six cam machines continue to be used.
However, capability to mill and turn parts of various levels of complexity in a single operation is dictating as much work as possible through the Citizen C16 and C32.
This is confirmed by Holliman, who reckons over 700 programs have been written since the machines were installed in April 2005.
Machines are often reset in the afternoon ready for the next job to run through the night and when the batch is completed, the machine switches off and is reset in the morning for the next part.
Due to the wide variety of batch sizes Holliman prefers to program at the machine while its running, working to the scheduled work load laid down by Elliot.
Far from sitting contemplating his life, Elliot is continuously busy.
He still goes to see customers, takes most of the phone calls to Quality Couplings and ensures all the machines are fully loaded with jobs.
'I issue the job cards manually - but early in 2007 we will be computerised, which will also help me control stock,' he said.
Computers will be an important addition to the citizen machines as with such a large customer base and a big demand for production call-off from stores for quick delivery, Quality Couplings has around GBP 1 million of finished stock components.
Other tasks performed by this most senior of managers is the raising of invoices and checking invoices from suppliers.
'There is no hierarchy in this business,' he said, 'I also do most of the quotes working with the setters to establish cycle times - well at least for CNC - I can still do cam machine quotes with my eyes almost shut, a factor of doing it for so long.' Both Citizen C-Series machines installed at Quality Couplings have main and sub spindles with two-gang tool slides enabling simultaneous machining with three tools.
The C32-VIII has an 8,000 rev/min main and 7,000 rev/min sub spindle with 14 tools and eight driven tools powered by 1kW motors.
The C16-VII has 18 tools plus eight driven by 1kW motors.
What has impressed Elliot is the support from NC Engineering.
'We had a couple of problems on a parts-catcher and for some reason a troublesome platen on the C16.
NC Engineering was able to locate and replace the platen the next day,' he said.
'Now that's what I call service,' he maintained.
While Elliot runs the day to day operation of Quality Couplings, his son, John 'junior', runs a submersible and surface pump supply operation from the same premises.
While not involved in his father's production interests, the two do vie for storage space and, with a knowing wink and a definite pride in his son's achievements, Elliot said he enjoys keeping the younger businessman on his toes.
'He's got to make space for my expansion,' maintained Elliot, 'Because I've got the bit between my teeth to adopt new technology and there will be more CNC machines installed soon.
The replacement of cam-driven turning with high-technology citizen cnc mill/turning machines has given John Elliot, the 83-year-old managing director of Quality Couplings, a new lease of life. 'The new machines have transformed the company,' he said, 'Giving me completely renewed interest - you could say I've developed a totally new outlook on life.' Following the installation of two Citizen C-Series CNC sliding head automatic lathes Elliot reflected: 'One immediate benefit of CNC technology is that we know exactly where we are with production, quality, delivery and price, and the company is already benefiting from reduced cost of production per part as the new machines are run unmanned at night.' That's a 'far cry' from the situation 12 months ago when he was facing the spectre of a future lack of skills for his traditionally bread-winning, but ageing, cam-driven machine based turning operation as four of his key autosetters (with 75 years service between them) look forward to retirement next year. He decided then it was time for a change and to adopt high technology mill/turning.
After spending some time looking at the leading CNC sliding head machines on the market, he decided in 2005 to buy the two Citizen C-Series machines from NC Engineering in Watford, UK.
These were installed in a refurbished factory unit just four units away from his cam machine shop and arrangements were made for NC Engineering to retrain an autosetter, Dave Reynolds, (who can tell the tales of some 50 years of being around automatic lathes) while 26-year-old CNC setter/operator, Paul Holliman, was recruited to run the new Citizen C16-VII and C32-VIII machines.
Born in 1923, Elliot left school at 14 to serve a seven-year apprenticeship as a pattern maker, followed by several years in the Merchant Navy during the war.
When he was 58, he bought Quality Couplings from The Receiver - at a time when many would rather be thinking of retirement rather than building a business - and moved the company from Birmingham to its current base in High Wycombe, Buckinghamshire.
He set about using traditional cam autos to produce turned parts for pipe fittings, and over the years progressively built a very successful business.
Today, he runs the two machine shops from an office on the shopfloor.
He wakes at 5 am every morning, arrives at work by 7 am and most evenings leaves at 4.45 pm on the dot.
In March next year, he is due to be featured in a Channel 4 television documentary.
Quality Couplings has a customer base of some 600 clients spanning heating and ventilation, gas burner, valves, pipe and hose fittings, pneumatics, heating, hydraulics and automotive suppliers, and it manufactures batches ranging from 500 to 10,000 parts.
CNC machining now takes priority at the firm ('Once established with the Citizens we despatched 11 cam machines to a company in Birmingham,' he said) though six cam machines continue to be used.
However, capability to mill and turn parts of various levels of complexity in a single operation is dictating as much work as possible through the Citizen C16 and C32.
This is confirmed by Holliman, who reckons over 700 programs have been written since the machines were installed in April 2005.
Machines are often reset in the afternoon ready for the next job to run through the night and when the batch is completed, the machine switches off and is reset in the morning for the next part.
Due to the wide variety of batch sizes Holliman prefers to program at the machine while its running, working to the scheduled work load laid down by Elliot.
Far from sitting contemplating his life, Elliot is continuously busy.
He still goes to see customers, takes most of the phone calls to Quality Couplings and ensures all the machines are fully loaded with jobs.
'I issue the job cards manually - but early in 2007 we will be computerised, which will also help me control stock,' he said.
Computers will be an important addition to the citizen machines as with such a large customer base and a big demand for production call-off from stores for quick delivery, Quality Couplings has around GBP 1 million of finished stock components.
Other tasks performed by this most senior of managers is the raising of invoices and checking invoices from suppliers.
'There is no hierarchy in this business,' he said, 'I also do most of the quotes working with the setters to establish cycle times - well at least for CNC - I can still do cam machine quotes with my eyes almost shut, a factor of doing it for so long.' Both Citizen C-Series machines installed at Quality Couplings have main and sub spindles with two-gang tool slides enabling simultaneous machining with three tools.
The C32-VIII has an 8,000 rev/min main and 7,000 rev/min sub spindle with 14 tools and eight driven tools powered by 1kW motors.
The C16-VII has 18 tools plus eight driven by 1kW motors.
What has impressed Elliot is the support from NC Engineering.
'We had a couple of problems on a parts-catcher and for some reason a troublesome platen on the C16.
NC Engineering was able to locate and replace the platen the next day,' he said.
'Now that's what I call service,' he maintained.
While Elliot runs the day to day operation of Quality Couplings, his son, John 'junior', runs a submersible and surface pump supply operation from the same premises.
While not involved in his father's production interests, the two do vie for storage space and, with a knowing wink and a definite pride in his son's achievements, Elliot said he enjoys keeping the younger businessman on his toes.
'He's got to make space for my expansion,' maintained Elliot, 'Because I've got the bit between my teeth to adopt new technology and there will be more CNC machines installed soon.
Sliding head automatic lathe deep-hole drills
CNC sliding head automatic lathe has a deep hole drilling facility and a motion control that allows very high speed cutting cycles for relatively simple turning operations.
A defining feature of the new Star SR-20RIII lathe compared with the RII model is its ability to drill a hole down the center of a 20mm diameter bar to a depth of 100mm, using the 3.7kW / 10,000 rev/min main spindle in conjunction with two additional front-facing tools mounted next to the opposed spindle. Another key feature is the Fanuc 300iS CNC with motion control, capable of very high speed cutting cycles for relatively simple turning operations when running programs created and optimised off-line using powerful computer-aided manufacturing software from Star. Conventional ISO programming and computer numerical control is reserved for producing more complex components.
The SR-20RIII will be demonstrated for the first time in the UK at customer launch days to be held at Star Micronics GB's technical centre in Melbourne, Derbyshire, on April 24-26 2007.
Star is also keen to point out that there will be special offers on certain machine models during the three-day event.
In addition, Iscar tooling will feature and Delcam will be making presentations on its Partmaker CAM software.
Managing director, Bob Hunt, is particularly pleased that the Japanese parent company has priced the new 7-axis mill-turn centre at a similar level as the original cost of an SR-20RII, so the additional RIII features are available at almost zero cost.
The specification of the RII has been reconfigured and will be offered alongside the RIII.
Further promoting high productivity are 35m/min rapid feeds in all linear axes, higher than on the RII and equivalent to the fastest machine in Star's range, the SR-10J.
C-axis positioning of the main and sub spindles in 0.01 deg increments is similarly fast at over 9 rev/s.
Despite the RIII's agility, it is a robust machine weighing 2.2 tonnes, capable of achieving very high accuracy and surface finish.
Spindle cooling ensures thermal stability and also contributes to high precision machining.
The working area can accommodate a large number of cutters in addition to the deep hole drills and the usual six ganged turning tools above the guide bush.
They include four front-facing and four rear-facing end-working tools in the main sleeve holder; up to 10 live cross-working stations, some of which may be swapped for more end-working tools or other attachments such as for angle drilling, hobbing or roller burnishing; and an independent, four-spindle back-working unit with live and stationary positions.
The design of a new product is not complete these days without measures to reduce its environmental impact.
A defining feature of the new Star SR-20RIII lathe compared with the RII model is its ability to drill a hole down the center of a 20mm diameter bar to a depth of 100mm, using the 3.7kW / 10,000 rev/min main spindle in conjunction with two additional front-facing tools mounted next to the opposed spindle. Another key feature is the Fanuc 300iS CNC with motion control, capable of very high speed cutting cycles for relatively simple turning operations when running programs created and optimised off-line using powerful computer-aided manufacturing software from Star. Conventional ISO programming and computer numerical control is reserved for producing more complex components.
The SR-20RIII will be demonstrated for the first time in the UK at customer launch days to be held at Star Micronics GB's technical centre in Melbourne, Derbyshire, on April 24-26 2007.
Star is also keen to point out that there will be special offers on certain machine models during the three-day event.
In addition, Iscar tooling will feature and Delcam will be making presentations on its Partmaker CAM software.
Managing director, Bob Hunt, is particularly pleased that the Japanese parent company has priced the new 7-axis mill-turn centre at a similar level as the original cost of an SR-20RII, so the additional RIII features are available at almost zero cost.
The specification of the RII has been reconfigured and will be offered alongside the RIII.
Further promoting high productivity are 35m/min rapid feeds in all linear axes, higher than on the RII and equivalent to the fastest machine in Star's range, the SR-10J.
C-axis positioning of the main and sub spindles in 0.01 deg increments is similarly fast at over 9 rev/s.
Despite the RIII's agility, it is a robust machine weighing 2.2 tonnes, capable of achieving very high accuracy and surface finish.
Spindle cooling ensures thermal stability and also contributes to high precision machining.
The working area can accommodate a large number of cutters in addition to the deep hole drills and the usual six ganged turning tools above the guide bush.
They include four front-facing and four rear-facing end-working tools in the main sleeve holder; up to 10 live cross-working stations, some of which may be swapped for more end-working tools or other attachments such as for angle drilling, hobbing or roller burnishing; and an independent, four-spindle back-working unit with live and stationary positions.
The design of a new product is not complete these days without measures to reduce its environmental impact.
Thursday, March 22, 2007
Manual/CNC lathe can also perform milling
The latest generation of advanced customised controls and conversational programming systems feature on the first Harrison manual/CNC lathe to have a milling facility.
The new Alpha X Series lathes from British lathe manufacturer T S Harrison, which was premiered at EMO 2005, features the latest generation of advanced customised controls and programming systems developed by Harrison design engineers in partnership with the industry-leading automation technology specialist, GE Fanuc. The Alpha X Series, comprising the XT, XS and top-of-the-range, 3-axis XM - the first Harrison lathe produced with milling capability - takes the Harrison range into a new era of performance, with significant enhancements in the crucial parameters of turning speeds, power and reliability. All new Alpha X Series lathes incorporate Fanuc's latest conversational programming software facility and offer the fastest, easiest set-up of any lathes in the market.
* Controls and control features - the 'entry-level' Alpha XT models (comprising the 1350XT, 1400XT, 1460XT and 1550XT) are all equipped with the GE Fanuc Oi Mate TC control.
This is loaded with the new Fanuc Turn Mate i conversational system.
The new controls for Harrison Alpha XT lathes feature: * 7.2in LCD mono operator touchscreens.
* ISO standard CNC.
* Full Fanuc CNC keyboards.
* One-click-one-micron feel handwheels.
* Sliding operator console for maximum convenience during loading and set-up.
* Rapid traverse joystick.
The Turn Mate i system on the XT models enables up to 40 separate operations to be stored in the software, allowing multiple options for profiling, grooving, facing, threading, drilling and tapping, radii and chamfers, boring, tapering and simple stops.
For the first time on the Alpha T range of machines it allows full contour programming at the control.
Another 'first' for the Alpha XT range, compared with the previous Alpha T models, is the ability to switch the control to full ISO functionality (CNC).
This empowers more experienced operators to run programmes previously used on other machines and/or to generate programs in the CNC format.
This is also the first time that any Alpha T model has been available with an eight-station bi-directional turret which increases its automation capability.
As with all previous Alpha machines, Harrison's Alphalink CAD/CAM software is supplied to customers free of charge.
The Windows-compatible system allows simple generation of standard ISO (CNC) programs and the use of previously-generated DXF files.
David Smith, Harrison's sales director, explained that the customized control system for the Alpha XT models has been extensively developed to provide a 'total system solution' for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.
'Like all versions of the X Series, the Alpha XT lathes are perfectly suited to producing 'one-offs' and small-batch turned parts.
No other lathes on the market today, including full CNC machines, can compete with the X Series for speed of production when it comes to these small volume turning applications,' he said.
The new Harrison Alpha XS line-up (comprising the 1350XS, 1400XS, 1460XS, 1550XS, and 1800XS), was similarly developed between Harrison and GE Fanuc.
The Alpha XS lathes have the GE Fanuc 21i TB control, loaded with custom-written Alpha mode programming software, which is unique to Harrison Alpha lathes, and the Fanuc Manual Guide i conversational programming system.
The key specifications are: * Ultra high-speed GE Fanuc 21i TB CNC control.
* 10.4in colour operator touchscreen.
* Two software systems (Alpha system + GE Fanuc Manual Guide i).
* Industry standard ISO programming.
* High-speed fibre optic data transfer.
* PCMCIA (flash card) and RS232 communication ports.
* Twin MPG handwheels.
* Rapid traverse joystick.
'The Alpha system software is well-recognised as the easiest control in the world to both learn and operate by a manual-lathe trained operator.
Its functions start with electronic stops, which directly mimic the familiar manual stops, and progress to automatic machining of complex forms.
At no time does the operator require any knowledge of CNC programming,' explained Smith.
'Manual Guide i is an easy-to-use, intuitive programming system designed to assist the less experienced operator to gain full advantage of the features of even the most complex of machining functions.
It is important to note this has been customised by Harrison to make the Manual Guide i fitted to these XS machines absolutely unique to the Alpha products and faster to programme than any other similar lathe.' The customised control system fitted to all Alpha XS lathes are designed to allow operators to utilize the machines to their full potential and capability with minimal training.
The Manual Guide i system offers a full range of easy, conversational cycles for direct 'at the machine' component set up.
Following programming the cycles may be simulated using 3D solid model graphics.
The new Alpha 1550XM lathe is identical in operation to the XS range, but has the additional functionality of a C axis and driven tool capability.
These machines utilise a standard headstock and newly-developed servo-driven worm and wheel drive.
Engagement of the drive to establish C-axis control is achieved via an electrically-driven actuator.
The tool-mounting options offered with the Alpha 1550XM are a Duplomatic 8-station turret (4 driven tool positions) or a Sandvik Capto driven tool-post allowing manual change of standard, Capto or driven tool holders.
To utilise the total C-axis capabilities of the machine, comprehensive C-axis programming cycles are available through both the Manual Guide i conversational system and the enhanced version of AlphaLink CAD/CAM software.
This total C-axis functionality allows milling, PCD (pitch-circle-diameter) and radial drilling, tapping, keyways, cam profiles etc to be generated off-line.
The new Alpha X Series lathes from British lathe manufacturer T S Harrison, which was premiered at EMO 2005, features the latest generation of advanced customised controls and programming systems developed by Harrison design engineers in partnership with the industry-leading automation technology specialist, GE Fanuc. The Alpha X Series, comprising the XT, XS and top-of-the-range, 3-axis XM - the first Harrison lathe produced with milling capability - takes the Harrison range into a new era of performance, with significant enhancements in the crucial parameters of turning speeds, power and reliability. All new Alpha X Series lathes incorporate Fanuc's latest conversational programming software facility and offer the fastest, easiest set-up of any lathes in the market.
* Controls and control features - the 'entry-level' Alpha XT models (comprising the 1350XT, 1400XT, 1460XT and 1550XT) are all equipped with the GE Fanuc Oi Mate TC control.
This is loaded with the new Fanuc Turn Mate i conversational system.
The new controls for Harrison Alpha XT lathes feature: * 7.2in LCD mono operator touchscreens.
* ISO standard CNC.
* Full Fanuc CNC keyboards.
* One-click-one-micron feel handwheels.
* Sliding operator console for maximum convenience during loading and set-up.
* Rapid traverse joystick.
The Turn Mate i system on the XT models enables up to 40 separate operations to be stored in the software, allowing multiple options for profiling, grooving, facing, threading, drilling and tapping, radii and chamfers, boring, tapering and simple stops.
For the first time on the Alpha T range of machines it allows full contour programming at the control.
Another 'first' for the Alpha XT range, compared with the previous Alpha T models, is the ability to switch the control to full ISO functionality (CNC).
This empowers more experienced operators to run programmes previously used on other machines and/or to generate programs in the CNC format.
This is also the first time that any Alpha T model has been available with an eight-station bi-directional turret which increases its automation capability.
As with all previous Alpha machines, Harrison's Alphalink CAD/CAM software is supplied to customers free of charge.
The Windows-compatible system allows simple generation of standard ISO (CNC) programs and the use of previously-generated DXF files.
David Smith, Harrison's sales director, explained that the customized control system for the Alpha XT models has been extensively developed to provide a 'total system solution' for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.
'Like all versions of the X Series, the Alpha XT lathes are perfectly suited to producing 'one-offs' and small-batch turned parts.
No other lathes on the market today, including full CNC machines, can compete with the X Series for speed of production when it comes to these small volume turning applications,' he said.
The new Harrison Alpha XS line-up (comprising the 1350XS, 1400XS, 1460XS, 1550XS, and 1800XS), was similarly developed between Harrison and GE Fanuc.
The Alpha XS lathes have the GE Fanuc 21i TB control, loaded with custom-written Alpha mode programming software, which is unique to Harrison Alpha lathes, and the Fanuc Manual Guide i conversational programming system.
The key specifications are: * Ultra high-speed GE Fanuc 21i TB CNC control.
* 10.4in colour operator touchscreen.
* Two software systems (Alpha system + GE Fanuc Manual Guide i).
* Industry standard ISO programming.
* High-speed fibre optic data transfer.
* PCMCIA (flash card) and RS232 communication ports.
* Twin MPG handwheels.
* Rapid traverse joystick.
'The Alpha system software is well-recognised as the easiest control in the world to both learn and operate by a manual-lathe trained operator.
Its functions start with electronic stops, which directly mimic the familiar manual stops, and progress to automatic machining of complex forms.
At no time does the operator require any knowledge of CNC programming,' explained Smith.
'Manual Guide i is an easy-to-use, intuitive programming system designed to assist the less experienced operator to gain full advantage of the features of even the most complex of machining functions.
It is important to note this has been customised by Harrison to make the Manual Guide i fitted to these XS machines absolutely unique to the Alpha products and faster to programme than any other similar lathe.' The customised control system fitted to all Alpha XS lathes are designed to allow operators to utilize the machines to their full potential and capability with minimal training.
The Manual Guide i system offers a full range of easy, conversational cycles for direct 'at the machine' component set up.
Following programming the cycles may be simulated using 3D solid model graphics.
The new Alpha 1550XM lathe is identical in operation to the XS range, but has the additional functionality of a C axis and driven tool capability.
These machines utilise a standard headstock and newly-developed servo-driven worm and wheel drive.
Engagement of the drive to establish C-axis control is achieved via an electrically-driven actuator.
The tool-mounting options offered with the Alpha 1550XM are a Duplomatic 8-station turret (4 driven tool positions) or a Sandvik Capto driven tool-post allowing manual change of standard, Capto or driven tool holders.
To utilise the total C-axis capabilities of the machine, comprehensive C-axis programming cycles are available through both the Manual Guide i conversational system and the enhanced version of AlphaLink CAD/CAM software.
This total C-axis functionality allows milling, PCD (pitch-circle-diameter) and radial drilling, tapping, keyways, cam profiles etc to be generated off-line.
Manual/CNC lathe expands turning capacity
Subcontract machinist said his customers knew he had acquired a manual/CNC (combination) lathe because he could make several parts in the time needed previously to machine one.
Chris Evans has been running Buckwood Engineering on his own for the past 20 years, and that is just the way he likes it. 'After 15 years in the family business, which employed 350 people, I decided I could do without the aggravation and set up on my own. I like being hands-on and will machine anything that comes my way.
I am never going to be a millionaire but I enjoy what I do.' Half of Buckwood Engineering's 1000ft2 premises at Markyate, Hertfordshire, is leased to another one-man engineering business, while the remainder is home to manual machines and, more recently, two manual/CNC machines supplied by Burlescombe, Devon-based XYZ Machine Tools.
Evans said: 'I bought an XYZ Edge 1500 manual/CNC turret mill as a replacement for an old manual turret mill and thought it would be my last machine tool purchase.
It proved to be an unbelievably good machine and I found myself taking a third of the time to complete a job, even though I had no previous CNC experience.
I did not even go for training because it is so easy to use.' Despite this success Evans continued to rely on a manual lathe until he realised that he was losing out on turning work from existing customers and decided to do something about the situation.
One month later, in January 2005, he took delivery of a new XYZ ProTURN VL 355 lathe equipped with ProtoTRAK CNC.
'My customers know I have the ProTURN because I can now make several parts in the time needed previously to machine one.
This allows me to quote lower prices while still earning enough to pay for the machine and to put money in my pocket.' According to Evans, he opted for the 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 because it matched the capacity of his DRO-equipped manual lathe while offering a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC control.
This flexibility is ideal for a small business like Buckwood Engineering that is called upon to machine a wide range of work pieces in varying batch sizes.
'There is not a turning job I can not do on the ProTURN because it is so simple to program, usually taking two to three minutes, and the program can be stored and recalled if I get a repeat order.
Although a one-off takes around a quarter of the time needed on a manual machine, a production batch probably takes 10 to 20% of the time, with a guarantee that every part will be identical.
I have just completed a 120-off job in a cycle time per part of six minutes compared with about an hour on the manual lathe, and within those six minutes I completed a second operation milling and drilling cycle on the ProtoTRAK mill.' Although adamant that the ProTURN lathe, definitely, is his final machine tool purchase, Evans says the move to CNC has made a very real difference to his life.
'I can now go home earlier that before, which allows me to indulge in my passion for chess, and I take regular holidays.
Chris Evans has been running Buckwood Engineering on his own for the past 20 years, and that is just the way he likes it. 'After 15 years in the family business, which employed 350 people, I decided I could do without the aggravation and set up on my own. I like being hands-on and will machine anything that comes my way.
I am never going to be a millionaire but I enjoy what I do.' Half of Buckwood Engineering's 1000ft2 premises at Markyate, Hertfordshire, is leased to another one-man engineering business, while the remainder is home to manual machines and, more recently, two manual/CNC machines supplied by Burlescombe, Devon-based XYZ Machine Tools.
Evans said: 'I bought an XYZ Edge 1500 manual/CNC turret mill as a replacement for an old manual turret mill and thought it would be my last machine tool purchase.
It proved to be an unbelievably good machine and I found myself taking a third of the time to complete a job, even though I had no previous CNC experience.
I did not even go for training because it is so easy to use.' Despite this success Evans continued to rely on a manual lathe until he realised that he was losing out on turning work from existing customers and decided to do something about the situation.
One month later, in January 2005, he took delivery of a new XYZ ProTURN VL 355 lathe equipped with ProtoTRAK CNC.
'My customers know I have the ProTURN because I can now make several parts in the time needed previously to machine one.
This allows me to quote lower prices while still earning enough to pay for the machine and to put money in my pocket.' According to Evans, he opted for the 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 because it matched the capacity of his DRO-equipped manual lathe while offering a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC control.
This flexibility is ideal for a small business like Buckwood Engineering that is called upon to machine a wide range of work pieces in varying batch sizes.
'There is not a turning job I can not do on the ProTURN because it is so simple to program, usually taking two to three minutes, and the program can be stored and recalled if I get a repeat order.
Although a one-off takes around a quarter of the time needed on a manual machine, a production batch probably takes 10 to 20% of the time, with a guarantee that every part will be identical.
I have just completed a 120-off job in a cycle time per part of six minutes compared with about an hour on the manual lathe, and within those six minutes I completed a second operation milling and drilling cycle on the ProtoTRAK mill.' Although adamant that the ProTURN lathe, definitely, is his final machine tool purchase, Evans says the move to CNC has made a very real difference to his life.
'I can now go home earlier that before, which allows me to indulge in my passion for chess, and I take regular holidays.
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