Heavy equipment machinery

A 5-axis machining centre of rigid portal type design and combining big capacity with a high level of structural robustness was shown at MACH 2006 alongside a universal bed-type miller

Ward Hi-Tech used MACH 2006 to confirm their position as one of the leading privately owned CNC machine tool distributors in the UK. With more than 60 models available from a portfolio of principal partners that include Doosan Mecatec of Korea, Dah Lih of Taiwan and CME of Spain the company showed a total of 10 CNC machines - including three new models.

Shown for the first time in Europe, the Dah Lih PT128 5-axis machining centre is of rigid portal type design combining big capacity with a high level of structural robustness.

CNC control is the Heidenhain TNC i530 Axis travels are X - 700mm, Y - 800mm, Z - 510mm, spindle speeds 15,000 rev/min, spindle taper BT40 and rapid traverse 30m/min in all axes.

The 40 ATC tool magazine is mounted separately from the machining area to prevent ingress of coolant and swarf and ensure the machine can be used to its full capacity.

The machine build incorporates a heavy duty trunion style 400mm diameter 5-axis table arrangement providing continuous 5-axis machining capability.

Unlike many 5 axis machining centres, at 14.000kg the PT128 is a true ‘heavyweight’ and is ideal for producing larger aerospace components that require true 5 axis capability.
Further reading

CME CNC millers suit mould and die machining
Universal bed-type and travelling column CNC milling centres and high speed, 5-axis bridge-type machining centres, manufactured by CME, Spain, are now being marketed by Ward Hi-Tech

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

* vertical machining centre - from the well known Dah Lih family of vertical machining centres the MCV-720 demonstrated its versatility machining a stainless steel aerospace component utilising an integrated 4th axis rotary table.

The MCV-720 is one of the best selling vertical machining centres in the UK and features axis travels of X - 720mm, Y - 460mm, Z - 510mm, spindle speeds of up to 8000 rev/min, 15HP main drive, 24 tool auto changer and standard specification is complete with high pressure through spindle coolant, bed wash, chip conveyor and table setting probe to provide a tremendous value for money package.

A feature of all Dah Lih machining centres is the on board ‘Manual Guide’ CAP system built into the Fanuc control.

This provides the user with a conversational programming system with colour graphics that can be used alongside or instead of the standard ‘G’ code format and is ideal for difficult programming operations.

* CME universal head, bed-type milling machine - from CME an example of this manufacturer’s large range of universal bed type CNC milling machines was on display throughout MACH.

The CME FS2 is equipped with Heidenhain TNC i530 CNC system and has axis travels of X - 2000mm, Y - 1000mm and Z - 1000mm.

Main drive is by 30HP motor and speed range 50-4000 rev/min provides a robust machining capability particularly in steel.

The heavy duty square ram is fitted with CME’s own design universal milling head with ISO50 taper allowing full power to be transmitted to the cutting tool in any horizontal or vertical position.

CME build bed type and travelling column style universal milling machines with X travels up to 20m and with specifications that can include high speed spindles up to 40,000 rev/min.

A 5-axis vertical machining centre with a rotating trunnion table allows the machining of complex multi-sided parts in a single set-up, thus reducing set-up time and increasing accuracy

One of the most time-consuming and costly components of any machining job is the initial set-up, especially for complex parts that require machining on multiple sides. Such parts often require multiple set-ups and complex fixturing, which can drive up the cost per part and result in less accuracy.

The new VF-6TR trunnion machine from Haas Automation allows full five-axis machining of complex multi-sided parts in a single set-up, thus reducing set-up time and increasing accuracy.

This unique machine is ideal for such industries as model making, tool and die and aerospace where complex shapes, multi-sided machining and five-axis work are quickly becoming the norm.

Based on the popular VF-6 (1626 x 813 x 762mm - X, Y and Z) vertical machining centre platform, the VF-6TR features a dual-axis trunnion table (in place of the standard T-slot table) which provides full five-axis simultaneous motion or can be used to position a workpiece to almost any angle for machining.
Further reading

Changing production standardised on CNC machines
Changing production over from single customised to volume-customised bikes introduced CNC machin tools but using similar programs and standardising on tool libraries from machine to machine

VMC offers thermal stability for precision
A high-performance vertical machining centre provides the accuracy, rigidity and thermal stability required for high-precision work, using massive cast-iron construction

The trunnion features travels of +/-120 deg of tilt on the A axis and a full 360 deg of continuous rotation on the B axis.

It accommodates parts with a swing up to 785mm and has a 225kg part capacity.

The trunnion’s 310mm platter features six precision T-slots equally spaced at 60 deg for easy fixturing.

Available in both BT-40 and BT-50 taper configurations, the VF-6TR comes standard with a side-mount tool changer, automatic chip auger, programmable coolant nozzle, Quick Code programming system, floppy disk drive, 1MB of program memory and remote jog handle.

Such high-productivity options as high-speed spindles, linear scales, High-Speed Machining with full look-ahead and several probe systems are also available.

MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.

Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.

More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.

Mori Seiki offers a wide variety of machines well suited for high-volume, agile and integrated production that will achieve the highest levels of efficiency and lowest cost per part

Featuring more than twenty ground-breaking machines, the Mori Seiki booth (A-8400) at this year’s International Manufacturing Technology Show (IMTS) will be the center for innovation and automation. The company’s revolutionary machines and software will be displayed in the metal cutting pavilion at the show, which runs from September 6-13 at McCormick Place in Chicago, Illinois, USA.

As a result of Mori Seiki’s commitment to research and development, the company continually designs new and innovative machines and software to provide the highest levels of value and productivity.

The company will be unveiling several new groundbreaking machines at IMTS, including the NT5400 DCG/1800SZ mill-turn machine, NMH6300 DCG horizontal machining center, NX3000 DCG production machining center and the NMV5000 DCG 5-axis machining center.

Making its international debut at IMTS, the NMV5000 DCG is the first machine in the NM Series of machining centers.

While extensive details will not be released until closer to the show, the new NMV5000 DCG is a ‘must-see’ for those interested in 5-axis machining.

Because Mori Seiki offers a wide variety of machines well suited for high-volume, agile and integrated production, the company can provide machines that will achieve the highest levels of efficiency and lowest cost per part, handle any challenge and maximize customer profitability.
Further reading

Machining centres apply full power at all speeds
Full power of the main spindle is applied at all speeds in a machining center for jobbing shops that combines high performance machining with reliability at an extremely competitive price

HMCs, VMCs and turning centre have common platform
Machine tool series features HMCs, VMCs and a turning center designed on a common platform, forming the ultimate modules for an automotive production line

Lathes offer robust milling capability
Focusing on increasing rigidity and minimizing thermal displacement to improve precision and productivity, mill-turning centres provide the roboust milling capability of a machining centre

Another key feature of Mori Seiki machines is the ability to automate manufacturing processes.

During the show, Mori Seiki will be demonstrating automation with its NZ-S1500 DCG 2-turret shaft lathe, NL3000Y/750 CNC lathe and NH4000 DCG horizontal machining center featuring a CPP (Carrier Pallet Pool) system.

To increase productivity, the NZ-S1500 employs a symmetrical design in which the two turrets are aligned with the spindle, which is mounted on the vertical bed.

This layout also serves to reduce the influence of heat and improve accuracy during continuous machining, holding thermal displacement to under +/-10 micron.

For the purposes of automation, the machine features a high-speed loader with a rotary hand function to increase the efficiency of the machine.

Mori Seiki’s powerful NH4000 DCG gives the customer the best in dynamic characteristics and surface quality.

The NH4000 DCG to be displayed at IMTS will feature Mori Seiki’s CPP (Carrier Pallet Pool) easy-order production system.

This unmanned system is capable of increasing the efficiency of any parts-machining production floor, while minimizing setup times.

Operators are able to control the system directly with a built-in operating panel, which showcases the system’s intuitive setup and user-friendliness.

The CPP system not only eliminates first article inspection, but also increases productivity.

The NL3000Y/750 provides milling performance equal to a machining center by placing the milling motor within the turret, and is perfectly suited for high-volume production.

As a result, the machine showcased at IMTS will feature a robotic arm to demonstrate its automation capabilities.

The NL3000Y/750’s milling capabilities reduce spindle time by 2/3 and vibration noise when compared to conventional models.

Its specially placed coverings redirect head out of the machine, which maintains thermal stability to improve precision.

Mori Seiki produces extremely reliable machine tools and distributes worldwide.

The US headquarters is in Chicago with offices in Boston, Chicago, Cincinnati, Dallas, Detroit, Los Angeles, and New Jersey.

IMTS demonstration uses a 5-axis horizontal machining center in a configuration optimized for titanium machining including patented ‘damping’ to virtually eliminate machining ‘chatter’

The rapid growth of composite aerospace structures has created a parallel demand for the complex, monolithic titanium components used to join them together. Aluminum, the traditional aerospace material, lacks corrosion resistance essential for this application, leading to an unprecedented demand for improved titanium machining capabilities.

Manufacturers of off-road and construction equipment, power generation systems and parts producing job shops are also machining more titanium.

Titanium’s outstanding combination of strength, light weight and corrosion resistance virtually ensures that this growth in demand will continue well into the future and with it, the need for more efficient production technologies.

Cincinnati Machine has responded to this trend by developing a suite of technologies and a network of affiliations that cover titanium processing literally from raw metal to chip disposal.

Focused on the goal of reducing the production cost of titanium components, ‘The Titanium Experts’ demonstrate their solutions in Booth A-8218 at IMTS 2006.

The demonstration uses the new Cincinnati Machine MEGA5 5-axis Horizontal machining center in a configuration optimized for titanium machining.
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 specific machine and process enhancements include: the application of patented ‘Damping’ technology to change the machine’s natural frequency and virtually eliminate chatter; a new coolant and coolant delivery system optimized for titanium machining; new tooling that delivers extended life cutting titanium; and an improved method of chip evacuation and removal.

The result is a nearly 100% improvement in throughput for the optimized machine compared to a conventional process for the same part.

‘The Titanium Experts’ have also applied their techniques to other Cincinnati Machine products that are highlighted at IMTS 2006.

These include Wide Range Profilers, the new U5-1500 Universal Machining Center, and the HyperMach router/profiler.

Attendees with questions relating to titanium part production are encouraged to visit A-8218 where ‘The Titanium Experts’ are available to answer questions, offer advice and demonstrate a variety of technologies.

The group includes experts in machine optimization, tooling, coolants and coolant delivery systems, titanium materials, chip handling and other disciplines.

* 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 and cells, including 5-axis and multi-tasking equipment.

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.

Multi-function machining centre can machine, turn and grind complex components and has an extremely fast tool-to-tool time of 1.1s that works with a 60 position tool changing system

Represented in the UK and Ireland by Leader CNC Technologies, Kitamura Machinery has just launched the revolutionary 5-axis Mytrunnion 1 machining centre at the recent IMTS exhibition in Chicago, USA. Capable of machining, turning and grinding complex components the Mytrunnion 1 is destined to be a success in the UK.

Equipped with an upgraded Fanuc 300iS control, the Mytrunnion 1 has been designed not only for high speed 5-axis machining; it can also turn components at 1,000 rev/min.

The machine also combines an optional 30,000 rev/min spindle speed with the rotary table for grinding operations.

With processing times of increasing importance, the Mytrunnion 1 has an extremely fast tool-to-tool time of 1.1s that works with a 60-position automatic tool change system that is fitted as standard.

The Mytrunnion 1 is ideal for medical parts, aerospace components, and similar complex parts up to 350mm in diameter and 215mm high.

Cooled ballscrews and scales are fitted as standard to achieve and maintain the extremely high accuracy.
Further reading

Wind turbines demand larger CNC machine tools
Concern over global warming and declining fossil fuels resources have caused a growth in wind turbine generator manufacture - and more demand for larger machine tools

VMC with advanced CNC saves 40% on machining
Using a vertical machining centre’s 15,000 rev/min spindle and the advanced look ahead features on its CNC, a company is realising 40% savings machining 3D profiles in advanced alloys

5-axis machining centre goes on show
Leader CNC Technologies, the UK and Ireland distributor of Kitamura Machinery has demonstrated the 5-axis Kitamura Mytrunnion 1 machining centre at an exhibition

Not only do these attributes make the machine ideal for tight tolerance components, it also guarantees exceptional repeatability.

To demonstrate this, the machine at IMTS was fitted with a 20 pallet system to exhibit the Mytrunnion’s capability to comfortably fit into a volume production or unmanned running environment.

For 5-axis machining, the Mytrunnion 1 uses an A-axis tilting trunnion fitted with an integral full rotary C-axis having a rotational speed of 1,000 rev/min.

The Mytrunnion 1 is also capable of heavy duty cutting.

This is provided by its hardened and ground box ways that have a dampening effect seven times greater than linear guide ways.

When combined with the high spindle torque, the Mytrunnion has a removal rate of 240cm3/min in S50C steel - exceptional for a machine of that size.

At under 7m2, the Mytrunnion 1 has been designed to take up less floor space, now at a premium in most companies.

This footprint is increasingly impressive when the overall capability of this machine allows it to finish components in a single set-up, usually in an area requiring a number of machines.

The Mytrunnion 1 is now in production and will be available from Leader CNC Technologies following the JIMTOF exhibition, in Japan, in November.

It will be exhibited in the UK for the first time at the Meditech Exhibition at the Birmingham NEC in February 2007.

Since the launch of the larger 630mm pallet Kitamura Mytrunnion vertical 5-axis machining centre in 2002, worldwide installations now number over 100 units.

Additionally, over 800 5-axis Supercell horizontal machines have been installed since 1981, confirming the capability of Kitamura to manufacture multi-axis machines.

High quality, high speed simultaneous 5-axis machining centres, offer superb levels of cost effective productivity in a small machine ‘footprint’ and perform extended periods of unmanned operation

With the advent of globalisation and high volume, low cost CNC manufacturing operations relocating to lower cost economies, Western manufacturers must adapt to a new business environment. Adding value and offering a rapid, unique and high quality production service is now paramount to any Western CNC manufacturing operation who wishes to compete in today’s highly competitive global marketplace - and to attract higher value work and subcontract business.

Enter the Matsuura MAM72 Series of high quality, high speed simultaneous 5-axis machining centres, offering superb levels of cost effective productivity in a small machine footprint and capable of extended periods of unmanned operation.

Since the MAM72 Series was introduced in their original incarnation in 1991, in excess of 500 machines have been supplied not only to some of the worlds leading companies and subcontractors - making some of the worlds leading products, but also to smaller ambitious machining concerns - each tailored and fully engineered to the customer’s unique process and business model.

The new MAM72-42V completes our leading range of integrated and dedicated simultaneous 5-axis machine tools - and we are confident that with the addition of the MAM72-42V we can offer an optimised and fully engineered exacting 5-axis solution that your process and business model requires - making any size component for any industry.

The MAM72 Series has the unerring ability to not only maximize a customer’s CNC 5-axis investment, but also has a proven track record for achieving a rapid return on investment.

Released with a vast array of options that can be tailored to your manufacturing operation, the key features of the MAM72-42V are as follows.
Further reading

Advanced 5-axis machining is unmanned
Intended for precision 250mm diameter x 250mm component manufacturers, an advanced 5-axis machining system, with 40 pallets allows long unmanned operation

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

* Unique and proven Matsuura A/C-axis table - designed, rigorously tested and proven on established Matsuura 5-axis products, the robust and highly accurate A/C-axis Table configuration contains Heidenhain’s renowned high resolution scale feedback system, assuring precise and reliable accuracy over many years of service.

Combining inherent high accuracy with high speed operation- A/C : 30/50 rev/min rapid and pinpoint indexing comes as standard with the MAM72-42V.

* Optimum machine structure for 5-axis machining - designed utilizing FEM analysis, the MAM72-42V possesses a highly rigid and optimized machine structure, offering huge strength and stability when performing simultaneous high speed 5-axis machining operations.

Containing the largest working enclosure and envelope in its class and sitting firmly in the middle of the MAM72 Series in terms of workpiece accommodation, the MAM72-42V’s capacity is impressive, to say the least, and capable of processing even the most unwieldy components efficiently and effortlessly - just like its larger stablemate, the MAM72-63V.

An optional tailstock is available on the MAM72 42V to offer further more rigidity when machining long, slender type components.

* Matsuura Hi-Tech spindle - the MAM72-42V utilises Matsuura’s latest Hi-Tech, grease lubricated Spindle - designed and built only by Matsuura, the pioneers of High Speed Spindles and machining.

Standard Spindle Speed: 12,000 rev/min.

Spindle Options: 15,000/ 20,000 and 30,000 rev/min.

Please call Matsuura for information on higher spindle speed options on 5-axis products.

* Optimised enclosure - the design of the machine’s enclosure,and the position of the NC operator panel allows total sight of the workpiece even when machining with the table at full tilt.

The position of the internal lighting also greatly assists all round enclosure visibility.

* Unique and proven APC design - incorporating Matsuura’s established ‘Flip Up Arm’ design, the integrated APC (automatic pallet changer) greatly reduces the machine’s overall footprint.

* Reliable swarf management - featured only on Matsuura Products, our X Type APC Door design removes all opportunity for swarf to become trapped and build up, eventually causing machine downtime.

By integrating steep angled steel Z-axis covers, swarf is efficiently directed into two gutters, where standard spiral chip conveyors rapidly transport waste material out of the enclosure.

To accommodate high volumes of metal removal of all types, a wide variety of swarf management system designs are available.

* Integrated Multi Pallet Linear System - With multiple installations in various configurations all over the world, Matsuura’s Linear pallet system will offer your business years of unmatched, reliable productivity and operation.

4- and 5-axis machines (horizontal and vertical) can all be served by the same Linear Pallet System, * Movement and ranges are as follows.

X-axis travel 520mm (20.47in).

Y-axis travel 730mm (28.74 in).

Z-axis travel 510mm (20.07in).

A-axis travel -110 to +10 deg.

C-axis travel 360 deg.

* Table and pallet are as follows.

Pallet working surface 300 x 300mm (11.81 x 11.81in).

Maximum work size on the table 420mm diameter x 350mm height (16.53in diameter x 13.77in) * Spindle (BT40) data is as follows.

Spindle speed range 40-12,000 rev/min.

Spindle bearing inner diameter 80mm (3.14 in).

Spindle motor power (continuous./short time) 7.5/11kW (15HP).

Maximum spindle torque 167Nm at 630 rev/min.

* Feedrates are as follows.

Rapid traverse rate (X/Y/Z) 50,000mm/min (1968.5in/min).

Rapid Traverse rate (A/C) 30/50 rev/min.

Minimum movement increment (X/Y/Z) 0.001mm (0.000039in).

Minimum movement increment (A/C) 0.001 deg.

* Automatic tool changer details are as follows.

Type of tool shank - JIS B 6339 40T.

Type of retention knob - JIS B 6339 40P.

Number of tools - 40 (chain-pot magazine type).

Maximum tool diameter 96mm (3.77in).

Maximum tool diameter 150mm (5.90in).

Maximum tool length 300 mm (11.81in).

Maximum tool weight 10kg (22lb).

Tool changing time - tool to tool - 1.1s.

* Automatic pallet changer details are as follows.

Number of pallets - two.

Pallet changing time - 18s.

Highly-rigid tilting rotary table of a recently-installed 5-axis machining centre enables workpieces, however complex their contours and features, to be completed in one set-up

5-axis machining centre has rigid rotary/tilt table Highly-rigid tilting rotary table of a recently-installed 5-axis machining centre enables workpieces, however complex their contours and features, to be completed in one set-up. A Mazak Variaxis 500-5X five-axis vertical machining centre is playing a key role in the production of the two-part aluminium camera bodies that house the complex electronics and imaging components of the Olympus i-SPEED 2 digital high speed video system.

Whether it is about improving manufacturing efficiency or contributing to automotive and aerospace safety testing, this new-generation product records fast-moving events and plays back images at much slower speeds, allowing the user to study events and quickly identify problems.

This is one of many innovative imaging products designed and manufactured in the UK that have propelled KeyMed (Medical and Industrial Equipment), a wholly-owned subsidiary of Olympus of Japan since 1987, to a second Queen’s Award for Enterprise.

Employing more than 1200 people in Southend-on-Sea and Plymouth (UK), Dublin (Ireland) and New York (USA), KeyMed has made rapid strides since it was formed in 1970 with a staff of four.

It currently claims market leadership for many of its product ranges, and to achieve this competitive edge in a global marketplace, KeyMed, which is accredited to ISO 9001:2000; ISO 13485:2003 and ISO 14001:2004, has invested heavily in its manufacturing facilities at Southend-on-Sea and its wholly-owned subsidiary, The Algram Group, in Plymouth.

The 7500m2 manufacturing facility at Southend-on-Sea is equipped for computer-controlled machining, laser welding, sheet metalworking, robotic welding, electrostatic painting, surface mount printed circuit assembly and automatic testing of electronic equipment.
Further reading

CNC mill-turn centre meets aviation needs
Aerospace subcontractor, Portsmouth Aviation was asked to produce components for next-generation defence programmes and an automated CNC multi-tasking mill-turn centre was acquired to do this

Check up on CNC machining at UK Autosport show
A mill-turn centre with Y-axis tool turret action will demonstrate the versatility of a machine that has won many customers in the autosport engineering industries

Larger VMC has 50 taper spindle
In response to market demand, including mould and die makers, a machine tool builder has introduced a larger vertical machining centre with a 50 taper spindle

It is here that the highly-rigid tilting rotary table of the recently-installed 30HP/12,000 rev/min Mazak Variaxis 500-5X enables workpieces, however complex their contours and features, to be completed in a single machine set-up.

Operating under simultaneous five-axis control, the table can tilt up to 150 deg (A-axis) and rotate up to 360 deg (C-axis), allowing unrestricted access when machining, for example, five sides of the i-SPEED 2 camera body.

In fact, the camera bodies are virtually fully machined in one hit as the final part of the machining involves removing material from the underside of the machined component to leave just two small ’snap-tabs’ on the completed profile.

Because KeyMed had previously sub-contracted its 5-axis machining work, Yamazaki Mazak UK supplied the Variaxis 500-5X equipped with a 30-tool storage capacity as part of a turnkey package that included CNC program development and associated tooling and workholding equipment.

‘We opted for Mazak because we know that the build quality is excellent and their service is equally good,’ said Alan Player, KeyMed’s Component Manufacturing manager.

‘We bought our first Mazak CNC machine in 1980 because we were convinced that its Mazatrol conversational control was the most user-friendly CNC available and we continue to program our Quick Turn CNC lathe and two Super Quick Turn mill-turning machines on the shopfloor.

However, we have now installed a Delcam off-line programming system as we are still on a learning curve with five-axis work.’ Player said: ‘Apart from the inherent complexity of components such as the i-Speed 2 camera bodies, we have moved away from making parts for stock to machining small batches for delivery direct to the assembly line.

This is on a four-hour forecast basis, so we cannot tolerate delays.

We are running a two-shift system at the moment but the level of demand for KeyMed products is such that we will be changing to a three-shift system in the near futur.

This makes machine reliability and the ease-of-programming aspect of the Mazatrol CNC more important than ever.

Because we are manufacturing smaller batch quantities, we are focused on reducing set-up times but we also need to keep the machines running and it is reassuring to know that operators can deal with any programming problems that may occur ‘out of hours’.

It’s all about ‘total cost’ in what is now a global marketplace, and that means avoiding unnecessary downtime and maintaining quality and delivery.’ Previously honoured in 2004 in the category of Sustainable Development - acknowledging KeyMed’s achievements in combining commercial vigour with progressive social and employment policies - this year’s Queen’s Award is in the category of International Trade.

An on-going R and D programme involving close liaison with Olympus in Tokyo has contributed to a 133% increase in export sales over the past six years, with KeyMed currently achieving overseas sales of more than GBP 76 million/year.

A 5-axis machining centre is capable of machining, turning and grinding complex medical parts, aerospace components, and similar complex parts up to 350mm in diameter x 215mm high

On stand E701 at the Medical Device Technology exhibition, UK, on 14-15th February, 2007, will be the revolutionary 5-axis Kitamura Mytrunnion 1 machining centre. Exhibited by the UK and Ireland distributor, Leader CNC Technologies; Kitamura Machinery has just launched the new machine that is capable of machining, turning and grinding complex components.

Suited to the medical sector and utilising an upgraded Fanuc 300iS control, the Mytrunnion 1 has been designed not only for high speed 5-axis machining; it can also turn components at 1,000 rev/min.

The machine also combines an optional 30,000 rev/min spindle speed with the rotary table for grinding operations.

With processing times of increasing importance, the Mytrunnion 1 has an extremely fast tool-to-tool time of 1.1s that works with a 60 position automatic tool changer, which is fitted as standard.

The Mytrunnion 1 is ideal for medical parts, aerospace components, and similar complex parts up to 350mm in diameter and 215mm high.

Cooled ballscrews and scales are fitted as standard to achieve and maintain the extremely high accuracy.
Further reading

Wind turbines demand larger CNC machine tools
Concern over global warming and declining fossil fuels resources have caused a growth in wind turbine generator manufacture - and more demand for larger machine tools

VMC with advanced CNC saves 40% on machining
Using a vertical machining centre’s 15,000 rev/min spindle and the advanced look ahead features on its CNC, a company is realising 40% savings machining 3D profiles in advanced alloys

5-axis machining centre goes on show
Leader CNC Technologies, the UK and Ireland distributor of Kitamura Machinery has demonstrated the 5-axis Kitamura Mytrunnion 1 machining centre at an exhibition

Not only do these attributes make the machine ideal for tight tolerance components, it also guarantees exceptional repeatability.

To demonstrate this, the machine at IMTS was fitted with a 20 pallet system to exhibit the Mytrunnion’s capability to comfortably fit into a volume production or unmanned running environment.

For 5-axis machining, the Mytrunnion 1 uses an A-axis tilting trunnion fitted with an integral full rotary C-axis having a rotational speed of 1,000 rev/min.

The Mytrunnion 1 is also capable of heavy duty cutting.

This is provided by its hardened and ground box ways that have a dampening effect seven times greater than linear guide ways.

When combined with the high spindle torque, the Mytrunnion has a removal rate of 240cm3/min in S50C steel - exceptional for a machine of that size.

At under 7m2, the Mytrunnion 1 has been designed to take up less floor space, now at a premium in most companies.

This footprint is increasingly impressive when the overall capability of this machine allows it to finish components in a single set-up, usually in an area requiring a number of machines.

Since the launch of the larger 630mm pallet Kitamura Mytrunnion vertical 5-axis machining centre in 2002, worldwide installations now number over 100 units.

Additionally, over 800 5-axis Supercell horizontal machines have been installed since 1981, confirming the capability of Kitamura to manufacture multi axis machines.

For further information on the MyTrunnion 1 or alternate solutions available from Kitamura and Toshiba Machine Tools or DMC turning centres, please contact Leader CNC or visit us at MedTec.

Three 5-axis machining centres are intended for precision engineering companies for the manufacture of medical devices (surgical and general instruments) and implants

Milling machine tool specialist - Mikron - part of AgieCharmilles GF has recently launched three 5-axis machining centres into the UK market. The machines - the UCP 600 Vario ProdMed; the HSM 400U ProdMed and the HSM 400U ProdMed Dental - as their names suggest - are all aimed at the rapidly- growing medical sector and, in particular, at precision engineering companies specifically involved in the manufacture of medical devices (surgical and general instruments) and implants (dental and orthopaedic, etc).

The medical sector is buoyant.

Increased life expectancy and the phenomenon of ageing populations (developed countries) - coupled with the rapid advances made in, and concomitant rise in demand for, cosmetic and reconstructive surgery and treatments - have created significant business opportunities for precision component manufacturers operating in the sector.

However, the sector is highly competitive - and, because medical components (implants), etc - are bespoke and are required in small batches (often one-offs) as well as being manufactured from tough materials - titanium, stainless etc - conventional machining technologies are often not up to the job.

The three machining centres span both High-Speed (HSM) and High Performance (HPM) milling technologies - and the machines provide users with the best of all worlds - increased productivity via automation, greater manufacturing flexibility, improved process reliability, high accuracy, optimised removal rates and excellent surface finish.

Here are some of the main highlights of the MedTech range of machines.
Further reading

Flood damaged wire EDMs replaced quickly
Areas of the UK suffered severe flooding in 2007 and a badly-hit EDM subcontractor had to replace its machines very quickly, aided by the UK subsidiary of a Swiss wire EDM machine builder

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

* Automation - on all ProdMed machines - integrated and high capacity tool changers (up to 220 position) and workpiece pallet changers (up to 48 pallets) ensure maximum productivity for low-to-medium volume production runs (characteristic of precision medical component manufacturing).

Such automated ATC and APC capability and capacity help manufacturers increase work throughput by reducing time spent on job setups and increase machine utilisation via unattended operations - resulting in reduced lead times and improved cost competitiveness.

Five-axis machining technology - the machines’ 5-axis capabilities too (enabling 5-face and/or simultaneous 5-axis and one-hit machining) - clearly also helps speed up production - and ensures greater precision and better finish by shortening part cycle times and reducing time and resources spent on setting up, fixturing, etc - all critical in making customised part manufacture economically viable.

* Spindle technology - irrespective of whether high, accurate material removal or fine finishing is required - the ProdMed machines with their StepTec high-performance, vector-driven HSK spindles (ProdMed Vario 20,000 rev/min and both 400Us at 60,000 rev/min) - can be relied upon to deliver.

The choice of spindle when manufacturing medical components is critical.

Workpiece materials - exotic alloys, titanium, aluminium, high chrome steels - are all difficult to machine.

The medical applications themselves and whether the requirement is for high material removal or super (polished) surface finishes or both - all mean that spindle speeds need to be optimised to the workpiece material and components in question.

The new MedTech machines, through their standard specification and options enable such optimisation to occur.

* Lubrication - ensuring that medical components are ultra clean is clearly of critical importance.

Depending on the materials to be machined and the application itself - customers have a choice of lubricant and lubricant delivery systems on the MedTech machines - water or oil-based.

* Swarf management - because of their integrated automation (ATC and APC) - the MedTech machines can run unattended - including ‘lights-out’, weekends etc However, to ensure that these productivity gains can be realised and to avoid problems such as workpiece and/or cutting tool damage due to poor chip evacuation and part contamination - the machines are equipped with sophisticated swarf management and chip removal systems.

* SMART technology - the MedTech machines are supplied with Mikron SMART technology software to optimise machining and ensure improved process reliability - by enable the user to make decisive interventions in the machining process in ‘real time’.

Said Mikron product specialist, Steve Burrows: ‘The new MedTech machines have created huge interest in the medical sector - and to date we have already taken significant orders from a number of first tier medical manufacturers’.

‘The interest in the new machines has now permeated to the medical precision subcontractor sector as well’.

‘In the next few months we expect sales to really take off.’ * About implants - an implant is an artificial device made to replace and act as a missing biological structure.

Outer shells of implants are often made of biocompatible materials such as titanium.

In some cases implants contain electronics, e g, artificial pacemakers and cochlear implants.

Some implants are bioactive, such as drug-eluting stents in the aorta and coronary arteries.

In Orthopedic surgery implants may refer to devices that are placed over or within bones to hold a fracture reduction - and prosthesis would be the more appropriate term for devices that replace a part or whole of a defunct joint.

In this context implants may be placed within the body (internal) or placed outside the body (external).

Dental implants are one of the few biomaterial devices which permanently cross the boundary between the inside and the outside of the body, since the base of the implant is Osseo-integrated in the bone of the mandible or maxilla and the top of the implant is in the mouth, where it can be capped with an artificial tooth.

Five-axis CNC machining centres are offered with optional linear motor drives to X and Y axes for those seeking the very latest in production technology

Introduced to the UK is a family of new 5-axis CNC machining centres from Nottingham-based, CMS UK, part of the Italian worldwide group specializing in solutions for machining all kinds of non ferrous materials. Typical applications include composites, carbon fibre, model block, aluminum etc, as used in many manufacturing industries including aerospace, motor sport, automotive, marine, rail transport, construction and buildings.

 linear drives - the standard Antares 5-axis CNC machining centre and its range of larger format Ares companions are now also offered with optional linear motor drives to X and Y axes for those seeking the very latest in production technology.

The Antares provides strokes of 2600 x 1500 x 1200mm while the larger Ares has three standard size options and can machine components requiring strokes of up to 6000 x 2600 x 1200mm.

The larger Ares machines, utilising a form of portal construction, are available in six different variants and permit the physical separation of the load/unload area from the cutting zone so that both operations can be carried out in tandem, thereby achieving maximum machine utilization.

* Design philosophy - according to CMS UK general manager, Toni Nagiel, the Ares/Antares concept deliberately tends towards a degree of ‘over-engineering’ in order to provide such a high degree of robustness, reliability and accuracy that the machines can be used with confidence for a wider range of applications than might previously have been envisaged.

This confidence in their capabilities is, he says, is being borne out by their increasing use in the high-tech industries.
Further reading

CMS UK now offers waterjet cutting systems
Tecnocut waterjet CNC cutting systems - with hundreds of systems installed worldwide - are now available from Nottingham based company CMS Group UK

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

* Aerospace - similarly, the materials regularly machined now extend through the more familiar mould, model and pattern-making, comprising wood, aluminum, epoxy paste and polyurethane to include structural light alloys and carbon fibre components as used, for example, in aircraft production.

* Pneumatic brake - one result of this design philosophy is to afford a far higher degree of stiffness to the 5-axis cutting head than is normally associated with machines of this type.

This useful attribute is further enhanced by the inclusion of a pneumatic brake that can be programmed to clamp the B- and C-axes during operations that do not require fully active 5-axis interpolation.

The PX5 universal head, with all five axes acting under simultaneous remote control from a GE-Fanuc 18i MB5 CNC system has, in addition to the three basic axes, a fourth axis that rotates around the vertical and a fifth that inclines the spindle in the vertical plane.

The highly specified NC control comes complete with PC Office integrated in the electrical cabinet.

* High speed - drawing on the parent company’s 35 years of experience, a particularly strong spindle shaft, made in-house, is mounted on two pairs of pre-loaded bearings - ceramic type for the front pair and steel for the rear pair.

This high-speed spindle (24,000 rev/min max 12kW or 27,000 rev/min maximum 6kW) is liquid cooled.

Fast positioning speeds of 70-80m/min are achieved along with acceleration rates of up to 3.0m/s2.

Automatic tool changing is linked to a tool-holder magazine located on the front face of the traverse and has an eight-tool magazine as standard or a 16-tool option.

According to CMS, the combination of a very high performance, powerful electro spindle and the machine rigidity assured by the mobile bridge-type construction, offer users ‘unmatched quality on a wide range of materials’.

* Extended markets - in extending the CMS market well beyond its original ones of woodworking and routing, the company is enjoying considerable success and, said Nagiel: ‘We are challenging manufacturers to look again at their previous understanding of what type of machinery they need’.

‘We are proving daily that, for many high-speed machining applications, equipment such as the Antares and Ares, with their large-volume working cubes, can be just as effective as higher-priced ‘traditional’ 5-axis machining centres.’ Nagiel mentioned how there can be a benefit to users by broadening their experience in this way and finds that ‘a little gentle education’ is often helpful.

* Vacuum workholding - cited are instances where the standard vacuum bed, for example, has provided an unexpectedly easy way for customers not familiar with the system to mount large components and save on tooling costs and downtime.

Nagiel went on to say, ‘Of course tee-slotted tables etc, are available as well, but production staff owe it to their companies to look at all options and, by dealing with CMS at its Nottingham base, they are talking directly to the machinery supplier and are offered full after-sales and technical advisory service from the same team.’