Five-axis VMC reduces job times by up to 50%
After selecting a 5-axis vertical machining centre from a ’shortlist’ of three, a motorsport subcontract machinist reported reduction in machining operations and up to 50% reduction in job times
A brand new Cincinnati CFV5-i five-axis CNC machining centre at motorsport subcontract machinist, Nicel Precision Engineering is having a profound effect on productivity, helping eliminate operations and reduce overall job times by as much as 50%. After working for many years in the motorsport industry, Kevin Banks opted to set up his own company, Nicel Precision Engineering, in 1999.
Located close to Northampton, UK, in ‘motorsport valley’, Nicel (pronounced ‘nickel’) has become so successful that it now boasts a strong connection with many high profile motorsport companies, including the Ford World Rally team and Cosworth Racing, which has awarded Nicel with ‘Grade A’ supplier status.
Key to the company’s success is its extensive manufacturing capability, yet until recently Nicel machined complex prismatic components in several operations using existing three-axis milling capabilities.
‘The time came to make a decision,’ said Banks.
‘We could continue with our existing process, or we could invest in new technology, eliminate operations, cut cycle times and move forward.
Although the choice seems obvious it was a big decision as we are still a young company with relatively modest financial resources.’ Having considered his option Banks decided to reinvest some of the company’s profits and purchase a 5-axis CNC machining centre.
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After narrowing a shortlist of suitable machines down to three candidates, the company opted to acquire a high performance Cincinnati CFV5-i with on-machine Renishaw probing.
‘The CFV5-i was the right balance between cost and specification,’ said Banks.
‘It was exactly what we wanted.’ Installed in February 2007, the machine has been set to work producing a host of complex parts for the motorsport sector, largely from exotic materials such as titanium and inconel.
Tolerances are often in the order of 0.01mm with typical batch sizes around 20-off.
‘To be honest we have kept the machine under wraps a little until now, so as to avoid over-capacity while we were getting familiar with the technology.
We have told one or two customers and already new orders have arrived for parts that previously Nicel would not have considered,’ said Banks.
By eliminating operations associated with manufacturing complex parts using three-axis machines, the benefits for Nicel have been considerable.
‘By making parts in a single operation on the CFV5-i, we not only reduce the number of operations, we also reduce the associated extra programming and planning,’ explained Banks.
‘I would estimate that we have cut total job times by as much as 50% in some instances.
This is a massive benefit in the motorsport sector where short lead-times and responsiveness are paramount.’ A case in point is an aluminium manifold component.
Machined on a boss, this part can now be attacked from five sides.
Firstly, as much two-axis conventional machining is completed before the component is indexed to machine the other planes, including the profile milling of external contours and bosses, counterbored and tapped holes, and the production of a 30mm long oval in the centre.
‘Machining parts such as these on our new CFV5-i has given us many advantages other than simply eliminating operations.
For instance, quality has been improved as we are making parts in a single set-up, and there is no longer the need to produce fixtures for three-axis machines to manufacture features such as angled holes,’ said Banks.
The CFV5-i provides full 5-axis capability at an extremely affordable price through its integrated rotary table solution.
The CFV5-i comfortably machines workpieces up to 400mm in diameter and 300mm high and it has up to 150 deg tilt capability.
A choice of leading CNC control systems is available to provide both positioning and simultaneous 5-axis machining capability.
Now with six employees, Banks has recently ‘retired’ from the shop floor to give more emphasis to company management.
‘This machine has enabled me to step back from day-to-day shop floor work,’ he said.
‘My operators have been given the Cincinnati training and I can now concentrate on talking to my customers, promoting the business and helping Nicel move forward’.
* About Cincinnati Machine - Cincinnati Machine designs, builds and sources high-precision machine tools for the global aerospace, automotive, mould and die, medical and general machining markets.
The company offers technology-driven solutions that include 3-, 4- and 5-axis CNC horizontal and vertical machining centres; and vertical, horizontal and multi-axis turning centres.
Cincinnati Machine in Birmingham, UK, is a division focused on the design, development, sales and marketing of the Cincinnati range of machine tools.
Cincinnati Machine Limited is a division within MAG industrial automation Systems, headquartered in Michigan, USA.
