The first model in the DMU 50V Series was unveiled in 1995 and by 1999, 600 units had been installed worldwide. The popularity of this universal milling machine has never wavered with successive generations. The DMU 50 eVo linear is a highly productive machine, able to accommodate a wide variety of 5-sided machining and 5-axes simultaneous contouring applications.

Despite a smaller footprint than its predecessor this machine has longer X and Y axes, 450mm and 400mm respectively.

It also boasts greater stability and rigidity.

As the suffix suggests, the 500mm X-axis is equipped with a dynamic linear drive that accelerates at 1G achieving rapid traverses up to 80m/min.

This represents an increase of 60% on the previous design, promising higher productivity and positioning accuracy.

The NC rotary table with 50 rev/min C-axis and 40 rev/min B-axis allows flexible 5-axis machining.

Its larger swivel range of 108 deg allows undercuts of 18 deg.

The universal design of this machine is complemented by the option to fit a 120-tool magazine as an alternative to the 30- and 60-station magazines whose double gripper reduces chip-to-chip times to less than 5 seconds.

The customer can choose from a range of spindle options - 12,000, 24,000 and the high-speed 42,000 rev/min types - and controls, Heidenhain iTNC 530, Siemens 840D powerline or MillPlus IT.

All feature the ergonomic DMG ControlPanel with large 15in TFT screen and 3D software.

Special packages, for machining aluminium or graphite for example, are also available.

Making its UK-debut, the CFV5 incorporates a dedicated table solution bringing full 5-axis, 5-sided large capacity machining capability to the popular range of tried and tested CFV vertical machining centres. The CFV5 with 5-axis integrated rotary table technology comfortably machines workpieces up to 400mm in diameter and 300mm high, and has up to 150 deg tilt capability.

Superior parts surface finish and accuracy is achieved from the high-rigidity cast frame structure, minimising chatter and vibration for a flawless finish.

A choice of state-of-the-art leading CNC control systems are available to provide both positioning and simultaneous 5-axis machining capability.

The popular ‘i’ version was demonstrated at MACH, with its optional 12,000 40 taper spindle, ideal for mould and die machining and aerospace structures, as well as general machining applications.
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

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 manufacturing plant and a focus factory for the design, manufacture, sales and marketing of the Blue Technologies ranges of machine tools.

Blue Technologies is a division of MAG industrial automation Systems, headquartered in Michigan, USA.

Other divisions within MAG IAS include Cincinnati Technologies, serving the OEM and Tier 1 aerospace market; Powertrain Technologies, serving the global automotive market with customised high-production solutions; and Maintenance Technologies, responsible for the global after-sales and service parts market for all MAG IAS customers.

The new FTV5 range, first shown at MACH 2006, is based on the Fixed Table (FTV) machining centre with a travelling column, the FTV5-1800 incorporates a 5-axis spindle head for full 5-sided machining. It is available in three X-axis range designations - 1800, 2500 and 3700mm, making it the ideal choice for aerospace, precision machining and die and mould applications.

The FTV5 with its integral HSK-63A spindle was presented at MACH with the Heidenhain iTNC 530 CNC and demonstrated the machining of a variety of materials from aluminium to hard steels, in 3-, 4- and full, simultaneous 5-axis modes.

The fixed table and extensive working envelope with Y-axis range up to 1005mm can incorporate heavy loads up to 10,000kg, ideal for machining heavy dies and large aerospace parts.

The FTV5 and FTV ranges of fixed table vertical machining centres are designed, manufactured and assembled at Cincinnati facility in Birmingham, UK.

* 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 manufacturing plant and a focus factory for the design, manufacture, sales and marketing of the Blue Technologies ranges of machine tools.

Blue Technologies is a division of MAG industrial automation Systems, headquartered in Michigan, USA.

Other divisions within MAG IAS include Cincinnati Technologies, serving the OEM and Tier 1 aerospace market; Powertrain Technologies, serving the global automotive market with customised high-production solutions; and Maintenance Technologies, responsible for the global after-sales and service parts market for all MAG IAS customers.

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.’

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

Large EDM benefits from advanced generator
Latest and largest EDM - with axis travels of X (U) 31.5in x Y (V) 21.7in x Z 19.7in uses CC generator, which boosts productivity and also preserves surface integrity of the machined material

High speed machining centres mill medical implants
High-speed and high-performance machining centers are specially suited for the manufacturing of medical implants, including dental and orthopedic, and also medical equipment

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.

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.

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.

Chiron has developed new high-power, long-bed, five-axis machining centre concepts that are specially tailored to customers in the aerospace sector. These include 5-axis Chiron Mill machining centres with a 90kW, 20,000 rev/min spindle that allow customers to explore new possibilities in highly productive aerospace machining.

The massively powerful spindle allows major savings in cycle times - with aluminium removal rates of around 2.1/2 lb/min.

As Chiron’s managing director Richard Blake explained, ‘One of the major issues within the aerospace industry is that maybe only 2% of the billet material ends up as product.

The rest has to be removed.

That’s why poundage is the key to being cost-effective.

Most machines currently in use in the aerospace sector only have 40kW spindles.
Further reading

Turning centre has Y-axis on three turrets
Among eight super high-precision turning centres is a machine with Y-axis on three turrets, while pallet handling and bar-feeders will also be shown including a serv0-driven type

Vertical machining centre has swivelling head
A 5-axis vertical machining centre features a thermally stabilised head with motor spindle that swivels about the B-axis, while the fifth CNC axis is provided by a horizontal rotary table

Five-axis vertical machining centre is affordable
Offering simultaneous 5-axis machining at an affordable price, a vertical machining centre gives maximum versatility, as the trunnion table can be quickly, and easily, removed for 3-axis work

The latest Chiron machines with spindles in the 90 to 100kW range allow you to cut faster for the more cost-effective manufacture of components.

On wing components, for example, it would not be unreasonable to expect a 40% reduction in cycle times.’ He said that many of the high-volume machine tool makers aren’t interested in offering this kind of special capability, and that Chiron has set out to offer something over and above other suppliers.

This is also true of the long bed sizes available in Chiron’s Mill range.

A typical specification might include a 3m overall bed length with a twin rotary table configuration, where each table could take components up to 1.25m in the X axis.

This compares to a maximum of around 800mm on most mass-market machines - and many wing components will not fit on this size table.

The Mill series machines also offer 60m/min rapid travels in all axes, spindle speeds up to 20,000 rev/min, HSK63 taper spindle nose and 30 bar through spindle coolant.

With its long bed, the machine layout is designed for optimum spindle utilisation.

The moving column, with vertical fixed spindle or tilting fifth-axis head can, for example, serve two rotary tables on either side of a mechanically operated dividing door.

While the components on one table are being machined the other table is being loaded and unloaded, so maximum uptime is achieved.

To support this high level of utilisation the Mill machine is fitted with a background tooling magazine holding 92 tools that works in conjunction with a tool changer within the machining column to give chip-to-chip times of less than 2.9s irrespective of where on the bed the column is.

Rather than simply supplying a machining centre, Chiron UK and its parent company, The Engineering Technology Group, can deliver a turnkey package, with zero point hydraulic or vacuum fixturing supplied by its sister company Hyfore Engineering, complete with all programs written, parts proved out and with guaranteed cycle times.

‘We believe that this ability of Chiron and The Engineering Technology Group to offer a total package is a major benefit for our customers - a total philosophy that other companies can’t offer,’ said Blake.

‘To stave off overseas competition we need to be at the forefront of technology in the UK.

If we are not exploiting it to its optimum effect then we will lose out to Third World labour rates.’

Matsuura has released the latest version of our globally acclaimed 5 axis CNC machine, the MAM72-25V. (MAM = Matsuura Advanced Manufacturing) Configured with 40 pallets in an exceptionally small machine footprint, this incarnation of the MAM72-25V is aimed at precision component producers who require proven unmanned running capability over long production runs.

Maximum component size is 250mm diameter x 250mm height (300mm diameter is optional).

APC (automatic pallet changer) options are: twin pallet/10 pallet/40 pallet.

A dedicated single table version is also available.
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

The MAM72-25V (all versions) is capable of holding up to 240 tools in its ATC (Automatic Tool Changer).

The PC40 and PC10 machines can be assigned to hold a variety of different jobs in the fully integrated high speed APC.

The NC is the powerful Matsuura G-Tech (Fanuc) 30i as standard, with the option of a Matsuura G-Tech (Siemens Yaskawa) 840Di.

As ever with Matsuura Products, all spindles available across the range are designed and built by in house by a dedicated team in a clean room facility in Fukui, Japan, a facility which is mirrored at Matsuura’s UK Operation in Leicestershire.

A BT40 15,000 rev/min Matsuura Hi-Tech Spindle comes as standard with the MAM72-25V, with 20,000 rev/min and 33,000 rev/min spindles available as options.

The MAM72-25V has proven to be a firm favourite with UK precision subcontractors and OEMs alike, with the majority of supplied machines being configured with either a 10 pallet or twin pallet APC.

Due to the growing requirement in the UK to compete with ‘low cost’ overseas operations, Matsuura has seen a dramatic rise in the number of multi pallet machines capable of proven and reliable unmanned operation supplied in the UK.

We consider our full range of machine tools to be at the leading edge of proven unmanned running technology.

On April 17-19, 2007, Matsuura will hold its annual Open House - theme being ‘Lights Out Manufacturing’.

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.