Five-axis machining centre cuts cycle times
What is believed to be the fastest 5-axis simultaneous machine on the market provides a subcontractor with ultra-fast machining capability and, as a consequence, reduced part cycle times
Brackley, UK-based Frazero is an internationally-renowned, market-leading automotive interior design and manufacturing specialist. The company, established in 1997 and now employing 30 people, has recently invested in a Mikron XSM 600U - a state-of-the-art high-speed 5-axis machining centre from AgieCharmilles GF.
The XSM 600U, acknowledged to be the fastest 5-axis simultaneous machine on the market, has been installed in Frazero’s CNC machining division where it sits alongside a Mikron UCP 600 - the first 5-axis machining centre invested in by Frazero in 2001.
The Frazero operation is niche and is highly specialised - and is divided into two main business areas.
The first of these focuses on providing conceptual solutions (e g, advanced design, development and engineering) to automotive OEM and first-tier suppliers.
This work is diverse and includes anything (and everything) from prototypes and one-off concept part manufacture through to production of complete car-concept interiors.
The company’s other division is less concept-oriented and more production-led.
Further reading
CNC wire EDM expands tooling inserts range
Manufacturer of tooling inserts has invested in a wire-EDM machine tool to broaden the variety of inserts offered in polycrystalline diamond and natural diamond materials
Five-axis machining produces complex parts
Direct drive, rotary torque tables on the latest 5-axis machining centres give fast and responsive 3+2 (positional) or simultaneous, highly accurate 5-axis machining
Affordable wire-EDM has flexibility
An affordable wire-EDM machine delivers reliable spark performance, flexibility, simplicity in programming, ease of work preparation and an aesthetic design, all at an attractive price
It is responsible for the production, assembly and delivery of car interiors - up to 3000 per year.
Frazero is predominantly involved with ‘prestigious’ automotive manufacturers and their brands - and has a world-class reputation in this luxury end of the market.
Customers include Bentley, Bugatti, Rolls-Royce, Jaguar, Ford, Lincoln, Cadillac, Morgan, Nissan and Spyker.
Frazero provides its customers with total systems solutions.
Typically this can involve advanced concept design using Catia V4/V5 and Icemsurf 3-D CAD modelling software packages.
The company also has a rapid prototyping and pattern-making facility to produce working parts quickly for early design studies.
The company’s previously mentioned machining division - not only has the recently acquired 5-axis machining capability in situ - but is also supported by other CNC milling and turning machines.
This division manufactures a wide range of quality components - where part accuracy and surface finish are at a premium.
Because a large proportion of car fascias, dashboards, consoles etc are manufactured from pressed and decorative aluminium - Frazero manufactures it own press tools to cut and form specific shapes in the material.
All ‘luxury’ car interiors exude quality - and the finishing touches and attention to detail are exceptional.
Wood veneering, high-temperature metal die pressing and polyester lacquering are all carried out in-house as are a wide range of composite, vacuum-formed and cast plastic mouldings.
Paint finishing, silk-screen printing and final component assembly are all similarly coordinated and managed by Frazero.
Recent projects undertaken by Frazero include - design, manufacture and assembly of the interior fascia and instruments for the Spyker C-8; engineering design and manufacture of the Bugatti Veyron centre console; the manufacture of interior components for the Bentley Continental GT at concept stage and the development of the wooden interior components; the design and manufacture of drinks cabinets, cup holders, humidors and many bespoke components for Rolls-Royce Phantom.
Frazero’s projects can all be characterised as low volume production.
They are also characterised by their high-precision, intricacy and attention to detail.
Manufacturing deadlines and lead times are always, it seems, very tight and extremely short.
To ensure that Frazero is always able to meet such stringent customer demands - the company has invested heavily in its CNC machining capability.
Only a few years ago the company subcontracted-out its machining requirements to local manufacturers.
Today, all manufacturing technologies and processes are in-house including high-speed, 5-axis simultaneous machining.
A remarkable transformation in just five years.
The investment in the Mikron XSM 600U is a further reminder of Frazero’s world-class status and future ambitions.
The machine with its 42,000 rev/min spindle; 80m/min feed rate and 25m/s2 acceleration/deceleration on X, Y and Z - provides Frazero with ultra-fast machining capability and, as a consequence, reduced part cycle times (from 2 hours to 20 minutes in the case of a Humidor - a glove compartment-housed cigar case) The XSM 600U’s large ATC (68 position) and equally impressive APC (seven pallets) provide Frazero with high productivity and uninterrupted machining.
The machine’s 5-axis capability (full 5-axis simultaneous machining and/or 5-face machining) means: fewer machining ops; less stop-start production; reduced work handling and ultimately improved accuracies and finish.
Said Brian Challenger, technical director at Frazero: ‘Our company is all about adding value - this is how we differentiate ourselves from our competitors.
Our recent investments in sophisticated and leading-edge technology (including our Mikron machines) help us maintain our competitive edge.’
