Steel Metal

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.
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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.’

High speed and high performance machining centres have been developed for producing medical implants and offer the reliability, traceability and accuracy that is required for medical parts

Mikron introduced their new ProdMed line of High-Speed and High-Performance Machining Centers that are specially suited for the manufacturing of medical implants, including dental and orthopedic, and also medical equipment, including surgical and general instruments. The new line of machining centers, including the HSM 400U ProdMed, HSM 400U ProdMed Dental and the UCP 600 Vario ProdMed, offer the reliability, traceability and accuracy that is required for machining medical parts.

The ProdMed systems include an integrated, automatic high-capacity tool changer of up to 220 tools and pallet changing device for efficient tooling and component changes, and offer a control system (Heidenhain iTNC 530) and smart machining modules that provide advanced monitoring levels that are critical for medical implant and equipment production.

This monitoring includes using measurements to check/evaluate tools and workpieces, inspect the tools for breakage, measure the workpiece and document all results.

In addition, the smart machine modules monitor spindle vibrations (Extended APS), automatically calibrate the machine geometry (ITC5X), and can transmit machine and process statuses messages to cell phones.

‘With the introduction of the ProdMed line, we are able meet the special demands for medical technology machining in terms of reliability, cost, exceptional finish quality of parts, and other stringent medical industry regulations,’ said Mal Sudhakar, vice president of sales at Mikron.

‘The medical parts industry is growing fast and Mikron is well-positioned to offer application-specific machining solutions for this industry.’ Machinists can choose the ProdMed system that suits their needs.
Further reading

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High speed machining centres mill medical implants
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Software manges EDM and process chain
‘Total package’ of software for managing and producing specific data for EDM machining aids in the organization of jobs and orders, job management and process chain

For machining titanium or high-alloyed steel, the HSM 400U ProdMed 5-axis (simultaneous), 30,000 rev/min models provide excellent surface finish and part detail while significantly reducing machining time for semi-finishing and finishing operations.

The high-speed and high-dynamic rotary axes facilitate the reduction of non-productive time.

The HSM 400U ProdMed is preferable for more complex machining operations with low to medium demands on material removal.

For Co-Cr alloys and other difficult-to-machine steel alloys, the UCP 600 Vario ProdMed 5-Axis (3+2 simultaneous axes), 20,000 rev/min system is recommended for machining work that is characterized by a high level of material removal.

All three ProdMed models feature an efficient chip and coolant management system that results in smooth production operations.

Mikron also offers its customers assistance and technical support that is critical for successfully producing the medical parts they need.

From advice on CAD/CAM issues, to questions regarding tool selection and other technical aspects, Mikron offers services which are vital for successful medical parts production.

* About Mikron - Mikron is a divsion of Agie Charmilles Corp, the world’s leading system provider to the tool and moldmaking industry.

The company provides sales, service, parts and technical support of Mikron high speed, high performance machining centers.

Mikron has the industry’s widest range of high speed machines, with travel ranges from 15 through 54in and spindle speeds up to 54,000 rev/min.

Machines are available in a wide array of three-, four- and five-axis configurations for die/mold, job shop, aerospace, medical, electronic and other high precision applications.

The company maintains fully equipped, state-of-the-art technology centers in Holliston, Massachusetts, and Lincolnshire, Illinois, for applications engineering, customer training and product demonstrations.

* Mikron on the Charmilles booth at IMTS 2006, Chicago, USA, September 6-13, Booth D-4000.

A 5-axis horizontal machining centre has special performance features including dynamic tuning, coolant delivery system options and tooling to boost titanium throughput by 50 to 100%

Cincinnati Machine introduced the new MEGA5-800 5-axis horizontal machining center at IMTS 2006 in Booth A-8218. Building upon the highly successful 4-axis MEGA Series, as well as Cincinnati’s 25 years of experience in the production of 5-axis horizontal machining centers, this machine promises to set the standard for performance in its class.

Utilizing the basic MEGA twin ballscrew-driven axes configuration in X-Y-Z and the basic MEGA B-axis table, the new 5-axis model incorporates an extremely compact A-axis tilt-spindle with 180 deg sweep.

This combination of standard features provides precision, five-sided machining capability for high quality, economical part processing, as well as full 5-axis contouring for processing highly complex parts.

* Optimized for titanium machining - the IMTS demonstration highlights Cincinnati Machine’s suite of technologies and techniques for high-efficiency machining of titanium.

The rapidly growing use of titanium in aerospace and other applications has focused industry attention on the need for improved processing capabilities for this ‘difficult-to-machine’ material, and Cincinnati Machine has responded with a comprehensive package covering machine dynamics, tooling, coolant delivery, chip handling, and even raw material characteristics.

Cincinnati Machine has equipped the MEGA5 with a combination of features that yields throughput increases of 50 to 100% compared to conventional processes.
Further reading

VMC reduces valve part machining time by 40%
Valve manufacturer reports that its latest vertical machining centre has machined a valve with 4,813 x 3mm diameter holes 40% quicker compared to the previous machine used for the task

Vertical machining centres take heavy loads
Cincinnati Machine exhibits at EMO 2007 will include vertical machining centes equipped for 5-axis and five-sides machining of workpieces up to 10,000kg

CNC machining centres keep to specifications
The ability of one supplier’s range of CNC machine tools ability to maintain productivity, accuracy and surface finishes over a long period of time led a precision machine shop to buy more

The company’s titanium process engineers are available in the Cincinnati Machine booth during and after demonstrations to answer questions relating to improving the productivity of titanium machining operations.

* Superior travels, speed and capacity - with its extended Y-axis, the MEGA5 offers 1425mm of X-axis travel, 1325mm of Y-axis travel, and 1265mm of Z-axis travel providing the range and part capacity to meet a wide variety of customer needs.

Part sizes up to 1300mm (51.2in) diameter and 2000mm (78.7in) high, weighing 2200kg (4840 lb) can be accommodated.

The machine’s feed rate of 60m/min (2,362in/min) and 1G (386in/s or 9.8m/s) acceleration/deceleration rate provide unmatched metalcutting performance compared to other machines of this class.

* Spindles for any workpiece material - the MEGA5 is available in machine configurations suitable for cutting a variety of materials.

The XT spindle configuration is intended primarily for hard metal applications.

The XT spindle package is available with a geared spindle providing a base speed of 375 rev/min and a maximum speed of 6,000 rev/min.

Duty rated at 45kW (60HP)/1,146Nm (845ft.lb) and continuous rated at 37kW (50HP)/942Nm (695 ft.lb), it is offered in either HSK 100A or ANSI 50 (ISO 7388.1) versions.

The MEGA5 AP spindle package is intended primarily for aluminum workpieces.

A choice of two high-speed spindles is available, one rated for continuous operation at 50kW (67HP) and the other rated at 30kW (40HP).

Both spindles feature HSK63A tooling interface and are capable of 24,000 rev/min operation.

* Proven components and design - the MEGA5 utilizes the same rigid, thermally stable symmetrical design as the previously introduced 4-axis MEGA machines.

The machine base incorporates an extra large center trough to handle high volumes of chips.

It also features three-point leveling in a compact footprint that eliminates the need for special foundations.

The A-axis tilt spindle used on the MEGA5 machine is adapted and refined from the spindle used on the highly successful Cincinnati Machine MAGNUM H5-1000 introduced in 1999.

* Minimized ‘parasitic’ time - in addition to its world-class axes rates, the MEGA5 incorporates other features to minimize non-cutting time and maximize throughput.

Equipped with the field proven automatic tool changer from the MEGA4, HSK100A or ANSI 50 tools weighing up to 30kg (66 lb) are exchanged in less than 2.5s tool-to-tool.

Lighter tools in the 0-to-5kg range can be changed in less than 2s.

The pallet changer is equally impressive, swapping 800mm x 800mm pallets in 14s.

The combination of speed and rigidity, along with minimized parasitic time and the reduced workpiece setup time, which results from the five-sided and 5-axis capabilities, increases the overall machine utilization percentage of the MEGA5 beyond that of a normal horizontal machining center.

* About Cincinnati Machine - Cincinnati Machine designs, builds and integrates advanced manufacturing solutions for the global aerospace, automotive, heavy equipment, energy and general machining markets.

The company’s broad machine tool line includes automated composites processing equipment, profilers, routers, large horizontal and vertical machining centers including 5-axis, multi-tasking and cells.

Cincinnati Machine, together with Giddings and Lewis and Cincinnati Automation and Test, makes up Cincinnati Technologies, a unit of MAG industrial automation Systems.

* About MAG Industrial Automation Systems - MAG Industrial Automation Systems (MAG-IAS), Sterling Heights, MI, is a group of leading machine tool and systems companies serving the durable-goods industry, worldwide, with a large portfolio of highly-recognized and well-respected brands.

With manufacturing operations on five continents, MAG-IAS ranks as a leader in the global metalworking capital equipment market.

A UK aerospace subcontractor has long experience of 5-axis machining and compares 5-axis with 3+2 axis capabilities, focusing on the importance of volumetric accuracy

An established practitioner of 5-axis machining for the production of medium-size aerospace parts, Oldland CNC wanted at the beginning of 2006 to extend its use of the technology to manufacture smaller components falling within a nominal half-metre cube. From a shortlist of five 40-taper machines, the Bristol subcontractor chose a German-built Hermle C 600 U vertical-spindle machine with 600 x 450 x 450mm working envelope and 30-tool magazine.

It was supplied in March 2006 through sole UK agent, Geo Kingsbury Machine Tools.

Whereas Oldland CNC extensively uses fully interpolative 5-axis profiling for producing aircraft parts that incorporate complex surfaces, full 5-axis machining on the Hermle accounts for only 10% of production.

The remaining 90% is 3+2-axis work, with two axes clamped while the others perform the cutting cycle.

Commented Oldland CNC’s managing director, John Tucker, ‘Smaller aluminium brackets on aircraft do not generally include complicated features needing full 5-axis machining.

However, simpler geometries benefit just as much from being milled on five sides in one hit using a 5-axis machining centre rather than in several set-ups on a 3-axis machine.’ He said: ‘We regularly evaluate components being produced on our 3-axis machines, looking for parts that will benefit from being positioned under CNC in a sequence of compound angles on the Hermle and milled using the other three axes.
Further reading

Subcontractor moves into 5-axis machining
UK subcontact machine shop has moved into 5-axis machining for high precision, small batch jobs for the aerospace, defence and motorsport industries

Subcontractor adds on 5-axis die machining
One often hears of troubled mould and die makers diversifying into subcontracting, but not so often does a successful subcontractor add on a 5-axis machining centre to do mould and die work

Modular tunnel washing machines are adaptable
Around 40 variants of modularly constructed tunnel washing machines allow systems to be configured from simple use to high volume production, and be expanded by retrofitting additional units

This approach can save one or two re-clampings and subsequent operations, leading to significant savings in production costs, particularly for larger batch work.’ Steve Hayes, engineering manager, Oldland CNC, suggested that moving all five axes simultaneously should be a last resort, as any 5-axis machine runs more productively in 3-axis mode.

Complex calculations that the control has to carry out prevent the use of fast feed rates in full 5-axis profiling.

Furthermore, the machine is only as quick as its slowest axis, usually the rotation of the table, so if that is one of the axes that are clamped, machining speed is increased.

High accuracy is a priority at Oldland CNC, a co-ordinate measuring machine being used for inspecting every component before delivery.

A feature of Hermle machines that Tucker particularly likes, and believes promotes precision machining, is the mineral casting that forms the bed.

It has good dynamic stability and up to 10 times better vibration damping characteristics than steel or cast iron, especially at high spindle speeds and feeds.

‘It is not a finely powdered mineral either - you can see large pieces of granite embedded in the compressed matrix if you look at a cut-away section of a bed in the Hermle factory, as we did,’ he advised.

Another design attribute he appreciates is Hermle’s patented arrangement of three staggered Y-axis guideways, one of which is positioned between two outer ways and set further back.

This effectively halves the span and gives stable traverse due to three-point support combined with a single drive in line with the central carriage on the gantry.

‘The ‘name of the game’ when producing high accuracy components, especially large ones, is not repeatability but volumetric accuracy of the machine tool,’ continued Tucker.

‘Manufacturers are often reluctant to disclose it, content to quote positional accuracy and repeatability in their catalogues.

Interestingly, Hermle does not appear to publish any accuracy figures at all; perhaps they do not need to.’ Tucker said: ‘In any case, for all of our machine tools we measure volumetric accuracy ourselves using a calibration ball and probe in the spindle.

It is the only way to determine how accurate features in a component will be, relative to one another, if they are machined in diametrically opposite corners of the working area.’ He said that when they checked the C 600 U, it had a total volumetric accuracy of 50 microns over the entire machining envelope, ‘Which I regard as excellent for a machine of this size moving in five axes.’ A majority of work going through Oldland CNC’s machine shop is for the Airbus family of aircraft - A300/310, A320, A330/340 and A380.

‘Round-the-clock’ operation continues from 6.00 am on Monday until 4.00 pm on Friday.

The Hermle’s maximum 16,000 rev/min spindle rotation is frequently used, although 12,000 to 14,000 rev/min is more usual, the elevated speeds enabling cutting feed rates between 5 and 10m/min, leading to high metal removal rates.

(A 40,000 rev/min spindle is optionally available on this machine).

Productivity is further enhanced by acceleration of 5m/s2 to 35m/min rapid traverse in all linear axes, and 5.5s chip-to-chip time.

When asked why he opted for a Hermle machining centre rather than one of the others on the shortlist, Tucker cited three main reasons.

First, the +/-115 deg swivelling trunnion carrying the 280mm diameter rotary table is an integral part of the machine construction, with the trunnion bearings set directly into the sides of the bed casting.

Some other machines offered a less robust solution involving a two-axis compound table bolted to the bed.

Secondly, all 24 machining centres on the shop floor have Heidenhain controls, so to facilitate operators swapping between machines, the new VMC had to be fitted with a control from that supplier - in this case the Ethernet-enabled Heidenhain iTNC 530 (although the Siemens S840D is available as an option).

Computer-aided engineering software in use at the Bristol site for off-line program generation includes Catia V5 CAD, MasterCam and CG Tech’s Vericut for simulation and tool path verification.

The third reason given for choosing Hermle was Geo Kingsbury’s good reputation for after-sales service, which has been confirmed in the first nine months of C 600 U ownership.

Horizontal machining centre incorporates linear motors on its tilting axis which allows all the 5-axis movements to operate at full speed and greatly increasing the machine’s overall performance

For the FIA Formula One World Championship season, Mercedes-Benz HighPerformanceEngines, Brixworth, Northants, UK, designs and manufactures F1 engines for Vodafone McLaren Mercedes. These support two cars for 17 races as well as an extensive development and testing programme. Many of the high precision engine components have different life expectancies and are replaced regularly throughout the season.

Mori Seiki’s relationship with Mercedes-Benz HPE goes back to its early days.

Shortly after the company (then known as Ilmor Engineering) was formed in 1984, two out of the first five machines purchased were Mori Seiki, and were destined for the manufacture of cylinder heads, connecting rods and engine blocks.

Now Mercedes-Benz HPE has 30 Mori Seiki machines and employs over 400 people.

The requirements of Formula One led the company to further develop the level of in-house machining in order to obtain the required quality, achieve rapid turnaround times, and also maintain confidentiality.

Adam Labudek, plant manager, said, ‘It is not unusual for us to work through the night to meet deadlines.
Further reading

Turning centre for precise components
A Mori Seiki NL2000SY Turning Centre was ordered on the stand at EMO Hanover show by Ottaway Engineering for the production of precise and intricate components

Mill-turn centre machines bike parts in one hit
Mill-turn centre cuts out the handling operations so that a mountain bike parts manufacturer can operate more machines with the same number of people, while reducing costs and improving quality

Machining centres and mill-turn centre unveiled
Three new machine tools from 27 exhibits on the Mori Seiki stand will be a 5-axis vertical and a horizontal machining centre, and a three-turret mill-turn centre with Y-axis

Our current machining capacity gives us maximum flexibility.’ The company originally chose Mori Seiki based on its reputation for reliability and accuracy.

The first Mori Seiki bought, a ZL25, is still machining crankshafts on its original spindle.

A MV40 machine purchased in 1989 worked reliably until recently, and is now waiting to be re-installed for the manufacture of jigs and fixtures.

Labudek said, ‘We carry out regular inspections, and these machines are within their original specification even after 18 years of use.

A number of our machines run 24/7 so the high standards of service and support we get from Mori Seiki are essential.’.

* Cell manufacture - the factory is arranged for cell manufacture with four or five machines per cell, each one dedicated to making particular components such as cylinder heads or camshafts.

The development machine shop is the exception.

This uses a MT203 mill/turn centre to provide the necessary flexibility for the wide variety of components, the rapid response, and batch sizes of one, which are required in this fast moving environment.

The company is an early adopter of new technology and uses the latest developments from Mori Seiki.

These allow it to implement new tooling and fixturing packages which optimise the benefits to be gained from the high spindle speeds and feed rates now available on the machines.

Labudek said, ‘Faster machines have enabled us to significantly cut machining times, while mill/turn machines have allowed us to reduce the number of operations, contributing to our ongoing high quality.’ Mercedes-Benz HPE and Mori Seiki have established a technical partnership in which the two companies work closely together to develop new machine designs to match the exacting demands of motorsport.

Labudek explained, ‘We have collaborated on a number of machine designs, including the NH8000 5-axis horizontal machining centre.

Mori Seiki engineers presented us with an initial scheme and invited us to comment.

For this machine we were concerned about the speed of the tipping axis compared with the speed of the other axes, which were extremely fast.

The new design incorporates linear motors on this axis which allows all the 5-axis movements to operate at full speed, greatly increasing the overall performance of the machine.

It is incredibly quick.’ From the initial concept to the final delivery of the first NH8000 it was just nine months - the company now has four of these machines.

Both Mori Seiki and Mercedes-Benz HPE benefit from the relationship by sharing technological expertise and practical experience in the most demanding machining environment.

Labudek concluded, ‘The high profile link to Formula One is undoubtedly a great benefit for Mori Seiki, while the leading edge machine tools which they supply, give us the capability to machine high precision parts quickly, reliably and to the highest quality standards.

It is a very valuable partnership for both parties.’.

* About Mori Seiki (UK) - Mori Seiki UK, the UK arm of Mori Seiki Co, Japan, services and supports Mori Seiki and Hitachi Seiki machines in the UK market.

Mori Seiki is one of the world’s leading manufacturers of metal cutting machines.

With its head office in Nagoya Japan, it employs 3,300 people, and is committed to innovation, quality, and service, with a range of machines to cover all industry sectors.

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.
Further reading

VMC reduces valve part machining time by 40%
Valve manufacturer reports that its latest vertical machining centre has machined a valve with 4,813 x 3mm diameter holes 40% quicker compared to the previous machine used for the task

Vertical machining centres take heavy loads
Cincinnati Machine exhibits at EMO 2007 will include vertical machining centes equipped for 5-axis and five-sides machining of workpieces up to 10,000kg

CNC machining centres keep to specifications
The ability of one supplier’s range of CNC machine tools ability to maintain productivity, accuracy and surface finishes over a long period of time led a precision machine shop to buy more

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.

Modified gantry design on a 5-axis vertical machining centre positions all guideways above the working area and Y-axis has a patented arrangement of three staggered guideways to give stable traverse

On display from Hermle, during the recent 50th Anniversary open day held by UK distributor, Geo Kingsbury Machine Tools, were three 5-axis, vertical-spindle machining centres (VMC). Each VMC has an integral, swivelling trunnion supporting a rotary table. The largest machine in the manufacturer’s C-Series, designated C 50 U, was demonstrated for the first time in the UK.

Capable of single-digit micron accuracy, its working envelope is two and a half times bigger than that of the next largest model in the range (C 40 U), extending the size of component that can be machined to 1000 x 1100 x 700mm.

Despite its large capacity and integral magazine that allows SK 40 / HSK A 63 or SK 50 / HSK A 100 tools to be picked up directly by the spindle, the machine occupies only 3 x 6.5 x 3.5m of space on the shop floor.

Production potential is high owing to 6m/s2 acceleration to traverse rates of 60m/min in the X- and Y-axis, 55m/min in Z, even though components can weigh up to two tonnes.

The modified gantry design positions all guideways above the working area.

The Y-axis has a tandem drive for high machine dynamics and features a patented arrangement of three staggered guideways, one mid way between and set back from the outer two.
Further reading

Subcontractor moves into 5-axis machining
UK subcontact machine shop has moved into 5-axis machining for high precision, small batch jobs for the aerospace, defence and motorsport industries

Subcontractor adds on 5-axis die machining
One often hears of troubled mould and die makers diversifying into subcontracting, but not so often does a successful subcontractor add on a 5-axis machining centre to do mould and die work

Modular tunnel washing machines are adaptable
Around 40 variants of modularly constructed tunnel washing machines allow systems to be configured from simple use to high volume production, and be expanded by retrofitting additional units

This halves the Y-axis span and gives stable traverse using three-point support.

Control options are Heidenhain iTNC 530 or Siemens Sinumeric 840 D, both enabled for modern Cube 67 / Profibus digital communication and networking.

Hermle offers multiple automation options for ‘lights-out’ running based on pallet change, transport and storage that either serves one machine, or can be extended to configure a flexible manufacturing system.

Likewise, there are robotic options for loading, handling and unloading components.

To give an idea of the machine builder’s capabilities in this area, the smallest C 20 U 5-axis machine was equipped with a PW 160 automatic handling and storage system for up to seven pallets of 500mm diameter or 400 x 400mm.

Capable of being factory-fitted or retrofitted, the system brings automation to the mould shop and complex component manufacturing environment, as pallets may be exchanged to and from the trunnion-mounted rotary table that provides fourth and fifth CNC axes in Hermle C-Series machines.

In its simplest form, the PW 160 handles three pallets using a rotating 2APC (twin automatic pallet changer) fitted with double grippers at each end.

It travels in the Y-axis direction, sharing its time between the machining area and a fixturing station at the front of the machine.

The design allows a component fixtured on a pallet to be introduced to the working area and production to start while the next component is still being set up, minimising idle time.

Additional flexibility can be obtained by increasing storage within the system to seven pallets.

An optional, four-pallet storage carousel is positioned to the side of the 2APC unit, exchange being effected by 180-deg rotation parallel to the X-axis.

Pallets with finished components and/or those awaiting machining may be parked in the carousel.

Pallet management software is built into the machine control, either a Heidenhain iTNC 530 or a Siemens S 840D, both of which are Ethernet enabled for networking.

Constructed on a mineral casting that provides stability for rapid, accurate pallet exchange, the PW 160 is easy to install, as it is a single-lift unit that does not need special foundations.

The footprint of the pallet changer is compact at 2.5m2 while that of the additional four-pallet store is only 1.0m2, so a full seven-pallet storage and handling system consumes only 3.5m2 of factory space in front of a machine.

Although the PW 160 is intended to facilitate automated running of a machining centre, the operator can nevertheless gain access to the working area from the side for manual intervention if necessary.

UK plant of Heller Machine Tools has noted a substantial rise in demand for its horizontal machining centres equipped with a swivelling spindle head for 5-axis working

Heller has reported that the demand for its MCH- C horizontal machining centres, which have a 360,000 x 0.001degree swivelling head, has increased beyond all expectation. The MCH-C has been introduced as an extension of the Heller MCH range. The managing director of Heller, Geoff Lloyd, said: ‘We believe that the increased demand for a simultaneous fifth axis capability stems from the great need for more flexibility in the machining process.

5-axis machining is no longer the preserve of the large, aerospace and automotive companies’.

‘Customers in all sectors of industry are looking for more versatility and an improved capability as well as seeking machine tools with which they can respond quickly and cost effectively to an unknown future demand.

Our swivelling head MCH machines are the ideal solution for many aerospace and automotive applications.’ The 5-axis MCH-C has been designed and manufactured to give maximum productivity, minimized piece part costs and therefore the greatest possible profitability.

The machine is powerful, dynamic and versatile and can handle parts of up to 4 tonnes maximum weight on a pallet size of up to 800 x 1000mm.

High machine tool dynamics give precise positioning and circular machining accuracy.
Further reading

Horizontal machining centres are very dynamic
Built for the production machining of non-ferrous metals, cast irons or hardened steels, Heller’s MCi dynamic horizontal machining centres have increased acceleration and precise positioning accuracy

HMC machines ‘intelligent’ transmission parts
When an engineering group sought a machining centre to machine aluminium transmission housing components it looked for a company to provide full production engineering support, writes Mike Page

High performance machining centre at Siemens
Heller deliver high performance MCi 25 horizontal machining centre for turbine blade production at Siemens power generation plant in Newcastle

The MCH-C’s drive systems ensure greater acceleration, increased drive power, and an extended speed range.

Options available with the MCH 4-axis horizontal machining centres are also available on the ‘C’ axis range.

These include Heller’s spindle power monitoring systems and drill breakage-sensing packages.

The fifth axis on the MCH-C allows simultaneous 5-axis machining.

The design also enables five-sided machining at freely selectable machining angles.

The range of the fifth axis is 360,000 x 0.001 deg.

Machine spindle speed is 6000 rev/min (option 8000 rev/min) and rapid traverse is 50m/min.

Chip-to-chip automatic tool changing time is 6.8s.

Maximum machine spindle torque is 822Nm.

Machine spindle taper is either SK50 or HSK A-100.

The tool magazine can be chain-type, with a maximum of 100 pockets, or a rack-type with a maximum of 405 pockets.

Both magazines have either fixed place coding or variable place coding for optimised pocket assignment.

* Machine structure and specifications - The MCH-C has a rigid, one piece, cast iron machine bed and a thermo-symmetrically constructed gantry column to ensure accuracy on the tightest toleranced parts.

Construction of the machine bed and column has been optimised through finite element analysis.

Guideways have pre-loaded roller bearings and a high positional accuracy.

Digitally controlled axis feed drives are integrated into the machine design.

The machine spindle is designed for easy maintenance combined with precise movement and has on-line thermal growth compensation.

The main spindle drive is equipped with precision bearings and is therefore free of transverse forces.

All bearings have metered oil-air lubrication.

Measuring scales are thermo-symmetrically mounted for precise direct path measurements.

Swarf removal is optimised by the use of steel swarf chutes and powerful scraping conveyors either side of the Z-axis.

CNC used in the MCH-C is the powerful Siemens Sinumerik 840D.

* About Heller Machine Tools - West Midlands based Heller Machine Tools provides a full turnkey engineering service from its manufacturing plant in Redditch.

Seven 5-axis, vertical machining centres, six equipped with individual 32-pallet storage systems, form the core of a Formula One racing team’s high performance prismatic metalcutting capability

Honda Racing F1 team reports a decrease in non-conformance reports, signifying a reduction in out-of-tolerance machined components, despite greatly extended use of unmanned production. It follows a GBP 4.5 million upgrade to its machine shop at the company’s Brackley, headquarters in Northamptonshire, UK, between Spring and Autumn 2006.

Seven new Matsuura 5-axis, vertical machining centres, six of which are equipped with their own individual 32-pallet storage systems, form the core of the prismatic metalcutting capability on the shop floor.

They are supported by two CNC wire eroders and a die-sinker, which are also new.

There are also four new 5-axis mill-turn centres.

Indeed, of the 20 machine tools now in place, only two were pre-existing.

Richard Smith, Honda Racing F1’s machine shop and fabrication manager, said, ‘Previously, during the build period from November to March, many of our higher cost components were produced by outside contract machinists.
Further reading

Toolholders offer high speed machining accuracy
CNC machine tool spindle toolholding products for high speed machining, suit the most arduous machining environments that require proven tooling and absolute accuracy

Five-axis machining used for cylinder blocks
A V8 cylinder block, machined from solid in one hit and possessing a near perfect surface finish was machined in a 5-axis machining centre working to tight tolerances

JJ Churchill Go 5 Axis with Matsuura
Leading Aerospace Supplier Invests in MAM72-25V Twin Pallet

Our aim was not only to reduce this, but also to have the capability to produce all of our components in-house and at the same time reduce set-up times and our dependency on using multiple machines to produce any given component.

He said: ‘In the first year we have put less work out to subcontract and are aiming to reduce it further.

As we have brought more production of the higher cost items in-house, in terms of value the saving to the team is greater.

We are a 24/5 operation with weekend cover when workload demands it during the F1 season.

Now that we have the unmanned running capability of the multi-pallet Matsuuras, we have been able to reduce the number of machine operators required to a skeleton team at the weekends and also during the night shift.’ He added: ‘This has reduced the need for staff to work continuously over the weekends throughout the build period and during the season to ensure that our concept-to-car lead time of between one and two weeks is met.’ Back in early 2004, Honda Racing F1’s board of directors was convinced of the benefits of moving from 3-axis and 4-axis to 5-axis machining so that parts could be machined in fewer operations, reducing or eliminating tolerance build-up and speeding throughput.

They also saw that multi-pallet machines would improve production output still further by minimising spindle idle time and maximising unmanned operation.

Several of the original machining centres did have twin pallet changers, but the facility was rarely used.

The real problem, though, was that the shop was dated and operators were constantly fighting the offsets on the machines to bring parts off to the required accuracy.

The problem was made worse by F1 car components becoming ever more complex and tightly toleranced.

At that point, Honda Racing F1 had the correct skill levels in the department but the equipment was struggling to keep up.

Two teams from Honda Racing F1 researched the market, one comprising management staff headed by Mr Smith and another made up of shop floor personnel.

Both teams independently agreed that Matsuura was the way to go, based partly on the Japanese manufacturer’s position in the top bracket of 5-axis machining centres.

More specifically, however, both teams arrived at the same conclusion owing to the small footprint of the 32-position, multi-level storage system for 350 mm diameter pallets, which can accommodate over 85% of machined parts used in Honda Racing F1’s cars.

Other machine tool companies could have supplied similar pallet storage configurations, but all would have needed a third-party storage system and consumed much more space.

To make sure that the decision was correct, a Matsuura MAM72-25V vertical machining centre was installed in 2005 as a test bed.

One of the trials successfully completed, which demonstrated a good saving in subcontract costs, was the machining of a batch of 15 hydraulic manifolds from solid aluminium.

The following year, the machine shop upgrade was carried out in four phases while production continued, albeit at a reduced level.

Six MAM72-35Vs with pallet storage systems were installed, plus a larger MAM72-63V 2xAPC dedicated to machining the gearbox main cases.

All of the other Matsuura machines are definitely not dedicated - quite the reverse.

A problem with the old production methodology was that certain types of component had to queue for particular machines, as they were set up for them in terms of fixtures, tooling and programs.

Such inflexibility, combined with the need for more second operations on 3- and 4-axis machine tools, created all of the classic problems of work-in-progress (production inventory) on a shop floor.

The most serious of these in such a frenetic F1 environment was slow progress of components through their production routes.

Now, most of the Matsuura machining centres are able to produce any component within its working envelope, thanks to all of the MAM72-35Vs having the same Fanuc-based control and an identical tooling library in the generous 240-station magazines that are fitted to each machine.

In addition, the 35Vs use a common fixturing method so each machine can accept any component fixtured on a 350 mm diameter pallet.

Honda Racing F1 has therefore been able to almost eradicate the bottlenecks caused by the different capabilities of the previous machines.

The high level of compatibility has resulted in much less queuing of components and their faster progression through the shop floor.

This is assisted by the machines themselves being fast, with 15,000 rev/min spindles (Matsuura’s own), 0.5s tool change, 40m/min feed rate in all orthogonal axes, and quick pallet indexing in the rotary B- and C-axis of 0.68s/90 deg and 0.69s/180 deg respectively.

Having up to 32 fixtured components waiting in each machining centre means that flexibility is high.

According to changing requirements at Brackley, either a production batch can be run or a rush job of a few parts can be completed equally efficiently.

Smith regarded the ability to combine batch production with cost-effective one-off machining of complex parts as a key benefit of the MAM multi-pallet concept.

He also pointed out that it is a big benefit not having to swap tooling between the magazines.

With 240 tools more or less dedicated to each machine and the security of in-cycle tip checking, the use of sister tools permits an approach to machining exotic materials like titanium and metal matrix compounds that is similar to the way in which aluminium components are produced.

The result is smooth, efficient workflow through the shop.

Workshop practice at Honda Racing F1 is for one operator to look after two machines and to be responsible for owning a job from program creation to component completion.

Multiple machine manning has been made easier by the reduced need for operator attendance, as confirmed by Smith’s concluding remark that a batch of aluminium pump housings recently ran unmanned on one of the MAM72-35Vs for 153h.