IS THE GEO KINGSBURY THEME FOR MACH 2012

The latest advances in CNC turn-milling, 3- to 5-axis prismatic machining and industrial cleaning will be promoted on the Geo Kingsbury Machine Tools stand at MACH 2012.

The company is sole sales and service agent in Britain and Ireland for Index, Traub, Hermle, Zimmermann, SHW and Dürr, all of whose factories are located in the technological powerhouse of Baden-Württemberg in southwest Germany. It is for this reason that Geo Kingsbury has chosen 'Made in Germany – Working in Britain' as the theme for its presence at this year's show.

A theatre for holding seminars and live demonstrations of two new turn-milling machines, the Traub TNL18-7B sliding/fixed-head lathe and the Index MS40 multi-spindle auto, will form a major part of the stand.

Protruding into the theatre to form the backdrop will be the working areas of both machines, each fitted with on-board video cameras. A central, 60-inch television screen will allow a seated audience to see every aspect of the setups and machining demonstrations in real time to convey the speed and ease with which the lathes can be changed over to a new job. The separate presentations on the Traub TNL 18-7B and Index MS40 will take place before and after lunch respectively, every day of the show.

To read the full editorial please click on the PDF icon above (PDF 263KB).

New product brings proven bioremidiating technology to the benchtop

Rozone, the leading provider of innovative, cost effective and sustainable cleaning solutions, has launched the PCS100 Benchtop Parts Cleaner; the latest bench top innovation in water-based cleaning that offers workshops a greener solution to parts cleaning, without the need for costly service contracts.

Using solvent free, water based cleaning fluid heated to just 40 degrees, the Benchtop Parts Cleaner from Rozone uses microbes to break down oil and grease so that it can then recycle the cleaning fluid, maximising its efficiency to achieve outstanding results. The Benchtop Parts Cleaner will significantly reduce hazardous waste disposal and completely remove the requirement for a monthly service contract.

Beth Jones, of Rozone commented “Water based bioremidiating technologies, such as those used in our PCS100 Benchtop Parts Cleaner, have improved significantly over the last 10 years which has prompted a move away from solvent based parts cleaning - across Europe it is estimated that there are already  more than 30,000 bioremediating systems in use. As this technology becomes increasingly common place we have found that there is a need for a smaller Benchtop system for use where floor space is at a premium, and that many of our existing customers want a mobile cleaning solution.”

Beth continued. “Our highly effective PCS100 Benchtop Parts Cleaner will bring to the workshop a small portable solution that will deliver an exceptional clean, with minimal environmental impact. As the Benchtop Parts Cleaner solution is non-toxic and vapour free, it’s also really safe for the user.”

The PCS100 Benchtop Parts Cleaner has a small foot print to fit neatly on top of a workbench, it’s easy to maintain, only requiring a regular top up of degreasing fluid and monthly change of the filter mat by workshop staff, and comes equipped with a flo-thru brush with self-cleaning jets to ensure that users can clean those hard to reach crevices.

To organise a demonstration of the PCS100 Benchtop Parts Cleaner or for further information, please contact Rozone on 0121 526 8181 or email info@rozone.co.uk

MAPAL, a global leader in high precision machining technology, has introduced what is believed to be the world’s first automatic tester for cutting tools used in MQL (minimum quantity lubrication) applications. This means that users of MQL technology, which typically reduces machining costs by 10% or more, can now test tools away from their machines, allowing them to increase productivity and further reduce their production costs.

In most cases, current users of MQL technology inspect tools directly on the machine before each use, but this means that the machine is effectively out of service while the inspection is taking place. Now, with the MAPAL UNITEST-MQL, the tools can be fully tested and inspected away from the machine, thereby greatly reducing costly machine downtime.

During its fully automatic test cycle, the new UNITEST-MQL sprays an oil and air mixture suitable for the intended machining process onto a test surface for a fixed time. The spray pattern for each of the cooling duct bores for the tool under test is then examined and compared with predetermined evaluation criteria. If the criteria are not met, corrective action, such as cleaning or adjusting the tool, can be taken before it is returned to service.

While the UNITEST-MQL is a very new development, MAPAL has already supplied the first production version to Ford-Werke GmbH in Cologne-Niehl, where it is being used to verify the performance of the MQL tools used for engine block manufacture without the need to interrupt the production processes. Ford has subsequently reported that its specifications relating to tool design, production quality and machining times can now only be achieved with the aid of the UNITEST-MQL.

Frank Clifford, managing director of contract machinist, Genhart Precision Engineers, operated cam-type sliding-head automatics extensively in the early 1980s. He later developed his Cheltenham company's turning expertise using fixed-head CNC lathes. Now he has come full-circle with the acquisition last summer (2011) of the subcontractor's first CNC slider – a Star SR-20RIII.

A feature of Genhart's business is its focus on very high accuracy work. Better than 5 microns total tolerance has to be held consistently on parts that Mr Clifford describes as 'fiddly', without recourse to lapping or other finishing processes. Aerospace, F1, telecoms and oil/gas exploration companies are typical recipients of the components, which are manufactured in anything from Nimonic, Inconel, high-nickel coppers and stainless steel through to brass and aluminium.

Solenoid valve manufacture is a notable area of expertise. It was one such component, made from 17-4PH stainless steel, that led directly to the purchase of the CNC sliding-headstock, multi-axis mill-turning centre.

Specifically, the SR-20RIII bar automatic was equipped with a special angle drilling head that has helped to cut floor-to-floor time for producing a particular valve part by three-quarters.

Star GB's engineers helped to develop the application, even to the extent of loaning the angle head at the outset to prove its effectiveness. The component formerly required four separate operations – fixed-head turning, milling, drilling and deburring – entailing a considerable amount of inter-machine handling and risking tolerance build-up.

The part, which is complex, is now produced in one hit on the SR-20RIII, including the angled hole, resulting in a significant reduction in production costs. Similarly, simple brass components are produced complete in cycles as short as 90 seconds, adding value without increasing manufacturing cost, particularly as such jobs can be left to run unattended during ghost-shifts after working hours.

The savings have prompted Genhart, a 25-employee company founded in 1979, to transfer many jobs from fixed-head CNC lathes to the slider, a process that is ongoing. Being able to turn near to the guide bush promotes the high accuracies that the company needs to achieve. Additionally, some shaft-type work such as hydraulic spools that previously had to be turned away, or subcontracted, is now done in-house.

Mr Clifford commented, "Learning to program the Star proved to be straightforward. We sent three operators on a training course provided by the supplier and they all picked it up quickly.

"We also find the lathe quick to set up and retool for the next job, lowering economical batch sizes.

"Before we bought the slider, our perception was that both of these aspects were going to be more difficult.

"Cheltenham seems to be a hot-spot for Star lathe users, so there were plenty of places nearby where we could see similar machines working before we took the plunge."

Genhart has been so pleased with its first sliding-head lathe purchase that it has placed an order for a second Star SR-20RIII, which is due for delivery at the end of February 201

...SUBCONTRACTOR FROM ITS COMPETITORS

Few contract machinists in Scotland have a modern, vertical machining centre to match the 2,200 x 1,700 x 750 mm capacity of the Hurco twin-column, bridge-type DCX22 installed at the Coylton works of Ayrshire Precision. This was precisely why managing director, Bert Bradford, purchased the machine on spec in February 2011. Since taking the plunge, the company has secured new work in each of its main industry sectors – mining, nuclear and oil / gas.

The first new job to come along was refurbishment of explosion-proof, steel covers for transformers used in coal mines. They are cooled by water flowing through a hollow jacket, the inner surfaces of which need to be roughened to create turbulence and increase heat transfer to the water. These and other plates up to four metres long are machined for the mining sector on the 50-taper DCX22, the larger workpieces requiring two clampings on the 2,100 x 1,600 mm table.

Forty-metre-long distillation tanks for nuclear waste storage require many large, high tensile steel panels to be machined and 25 such vessels are planned in the UK to cool and make safe spent radioactive material. Ayrshire Precision has won a contract to contribute to this project, which involves not only milling the panels but also drilling large numbers of holes to accept temperature probes.

More recently, 500 mm diameter flanges for the oil industry have been machined cost-effectively on the DCX22, the first such machine to be installed in Scotland, thanks in part to the ability to set up four at a time on the table. Each flange requires milling and drilling of 16 holes. Centres have to be within ± 25 microns, while the tolerance held on a sealing groove is 18 microns total.

All four parts are completed in one hit to minimise tool changes and maximise production efficiency. Moving from one part to the next is achieved rapidly and automatically using the 'work offset' feature of WinMax, the conversational programming software in the proprietary Hurco control system. The same feature can be used for multiple part machining, even when setting up dis-similar jobs for unattended running.

To maximise, flexibility, Bert Bradford bought a universal angle head from Hurco for use on the DCX22, which is proving especially useful for machining internal slots and angled holes. A separate WinMax module was written by Hurco to accommodate this extra facility.

Mr Bradford commented, "During the MACH 2010 exhibition in Birmingham, Hurco gave a good demonstration of their WinMax-based twin-screen control system.

"We use the menu-driven, conversational programming nearly all the time, as it is so quick and easy at generating cutting cycles for our jobs, which in most cases are relatively simple. Occasionally we will program off-line on our Edgecam system for more complex work.

"The DCX is our first Hurco machine, but our lead programmer, David Torbet, had no trouble picking up WinMax and our other machine operators can use it as well."

Unique geometry promotes high penetration rates in steel components

Cutting tool and tooling systems specialist, Sandvik Coromant, will launch the fastest solid carbide drill available on the market, CoroDrill® 860.

Providing expert support to manufacturers.

13 February 2012 – Halesowen - Sandvik Coromant has announced a partnership with Heller Machine Tools following the installation of the state-of-the-art FT 4000 machine at the company’s Productivity Center in Halesowen, West Midlands. The significant Heller investment will enable Sandvik Coromant to take a step forward in providing expert support to manufacturers across the UK operating in a wide range of sectors including aerospace, automotive and the oil and gas industry.

Photograph from: left - Geoff Lloyd, Managing Director of Heller Machine Tools, Klas Forsström, President, Sandvik Coromant and Magnus Ekbäck, Managing Director, Sandvik Coromant UK with the FT 4000 now in situ at the Sandvik Coromant Productivity Center.

1.8kw Bystronic Bysprint 3015 laser 1999 cuts up to 12mm mild.

New turbo 18months ago. 16,000 hours. With Sheet loader.

 BROADBENT LATHE

Description: 
5 M BC
1965 MM swing
gap two face plate two steady 3 and 4 Jaw chucks

OUR MONTHLY SALES FLYER HAS THOUSANDS OF PRODUCTS COVERING ALL OF OUR MAJOR PRODUCT SECTIONS:

View our SPECIAL OFFERS flyer now and order directly off the page for a next day delivery!

• Hole Making
• Threading
• Milling
• Turning Tools
• Tool Holding & Work Holding
• Machinery
• Hand Tools
• Measuring Instruments
• Personal Protective Equipment
• Abrasives
• Air & Electric Tools
• Adhesives & Lubrication
• Material Handiling & Storage
• Raw Material & Fasteners

All from leading brands in the industry like: 3M, Bosch, DE-STA-CO, Dormer, Eclipse,  Facom, Gerardi, Guhring, Hertel, Kennametal, Kitagawa, Norton, Rohm, Ruko, Sealey, Seco, Stanley, TOS, Vargus, and many more all at great prices!

Log onto our website for more information about our services and scope of supply.

Or

Please call our Customer Service Team on our free phone No: 0800 66 33 55

A feature of the NCMT stand will be the Speroni ESPERIA STP46 tool presetter. Of rigid construction and designed for shop floor use, it incorporates a novel taper adaptor and a claw system that accommodates all pull stud designs, allowing changeover for setting different tool tapers in just eight seconds. Repeatability of positioning is to within half a micron.

As with all Speroni tool presetters, the thermo-balanced structure is made of artificially aged, pearlitic cast iron to ensure the equipment is fully isostatic and will not deform or distort over time or as the temperature changes.

Unlike most presetter designs, the homogeneous structure avoids the drawbacks of systems that use light alloys and/or granite, which have different and unstable reactions to changes in temperature and the environment. There is consequently no need for frequent recalibrations during a shift due to temperature changes.

Both hardware and software are developed and produced in-house by Speroni, whilst peripheral equipment is sourced from the very best suppliers – Schneeberger linear guideways, Heidenhain encoders, Sony camera, etc.

Okamoto's new ACC64CA-iQ surface grinder will be demonstrated for the first time in the UK.

Rigidity of the column, bed, table and guideways combined with 7.5 kW direct drive to the grinding wheel minimise vibration and deflection, even when running at full power with a workpiece of up to one tonne on the 600 mm x 400 mm table. A 40 m/min linear motor performs the longitudinal axis motion, helping to endow the machine with 40 per cent higher productivity than previous comparable grinder models.

Compared with other machines in its class, the grinder provides some of the highest levels of functionality in terms of ease of set-up, simplicity of use, reliability and accuracy. The column effects the cross movement, rather than a saddle as in smaller models, giving easier access for loading and unloading larger workpieces.

Super-precision, pre-loaded ball bearings ensure wheel spindle stiffness. The grinding wheel is 355 mm diameter by 38 mm wide wheel and rotateat 500 to 2,500 rpm. Two separate downfeed rates may be set from 0 to 30 microns for coarse feed and 0 to 10 microns for fine feed, change points being independently adjustable.

Sparkout is set between 0 and 99 reciprocations. Wheelhead feed can be performed manually via an electronic handwheel in three increments – 0.0001, 0.001 or 0.01 mm.

The machine on show will be fitted with an easy to program, conversational, 2-axis CNC system. Until recently, complex grinding tasks relied on the experience of a skilled operator. The development of the new Okamoto iQ touch-screen control and its easy to use software, coupled with the machine's inherent mechanical accuracy, allows impressive results to be achieved by anyone. By breaking down complex tasks into simple, basic operations, even unskilled operators can use the machine with maximum efficiency.

Setting is divided into two parts: wheel dressing and grinding. A logical graphical representation of each of these operations serves to guide the operator through the setting process. It is made even easier by the use of easy to understand icons displayed on a generously sized colour screen.

Although Okuma's TurnCut software was introduced as far back as EMO 2007, MACH 2012 will mark the first demonstration at a national UK exhibition of this highly productive machining process.

NCMT is keen to promote it further, as despite it being a difficult concept to describe, once manufacturers adopt it, as several in the UK already have, the productivity gains can be enormous for the right applications.

The patented software provides a new, faster and more accurate way of turning tapered bores and outside diameters using Okuma horizontal machining centres. Components requiring turning as well as prismatic machining may therefore be produced in fewer set-ups, leading to cost reductions and greater accuracy.

Turn-cutting is a cost-effective and very accurate alternative to established ways of turning on a machining centre, namely using either a facing head or a rotary table and a static turning tool in the spindle. Even when a family of straight bores is being cut and taper turning is not employed, the technique is still cost-efficient, as it avoids the need to purchase a number of expensive boring bars.

TurnCut software runs in the OSP-P200M control of Okuma horizontal machining centres. At MACH 2012, visitors will be able to see a video showing how a single-point tool in the spindle is able to turn a static component by rapid circular-interpolation of the X and Y axes while feeding forward in Z. As the workpiece does not move, eccentric components can be machined as effortlessly as those that are symmetrical.

The clever part, which forms the core of the TurnCut patent, is the ability of the control to continuously orientate the tool in the spindle by rotating

it at precisely the same speed as, and in synchrony with, the circular X/Y path. The tool therefore cuts at the correct rake angle at every point throughout the 360-degrees to ensure efficient and precise metal removal. Linear feed rates of up to 60 m/min allow a wide spread of rotational cutting speeds to be generated.

Cylindrical bores and ODs are easily achieved by keeping the X/Y travels constant, while tapers and other profiles can be turned by varying the amplitude of circular interpolation. Accuracy to within microns is achieved and it is this degree of precision that is crucial. Some machine manufacturers might be able to approximate the procedure, but only for open-tolerance work.

New turning machine to make UK debut & machining centres also to be announced

NCMT will launch at MACH 2012 a new range of early-entry machine tools from Okuma, a Japanese manufacturer better known for its high-end machining centres and lathes.

Called GENOS, the programme comprises two machining centres and fourteen CNC turning centres, one of which, a twin-spindle model, will be under power at the show.

The GENOS series started with the development of the M460-VE vertical machining centre with 762 x 460 x 460 mm axis travels. It was followed by the M560-V with 1,050 x 560 x 460 mm working envelope that also extended maximum table load from 700 to 900 kg. Both machines feature a CAT40 BIG Plus spindle moving in the X and Z axes, with the table moving in Y.

A 30-position tool magazine and Okuma's own OSP-P200M control are provided. Software can be added, such as Machining Navi L-g to find the best cutting conditions for minimum chatter, and CAS for collision avoidance.

The 14 lathes offer a variety of combinations of spindle, bed size, tool turret, static or driven tooling, Y-axis, and tailstock or counter spindle. There is also the option of robotic or other automated systems for workpiece load / unload.

The GENOS lathe on show will be the 10-inch chuck L300MW, which has a 6,000 rpm counter spindle with a 520 mm W-axis stroke. Together with C-axis on the 3,000 rpm main spindle, plus programmable linear motions in X and Z but not Y, the machine offers four CNC axes for one-hit mill-turning in combination with 12 live positions in the turret. Interestingly, its Prex motor is responsible for turret index and tool drive, simplifying construction and reducing heat generation. Maximum turning diameter is 300 mm.

GENOS machines have fewer standard functions and options than other Okuma lathes, allowing the lower price point to be achieved. There has, however, been no compromise on build quality. The manufacturer is renowned for manufacturing, and hence being able to control the quality of, the majority of components that go into its machines, including drives, encoders, scales, and ballscrews. These are also to be found in all the entry-level GENOS products.

Multi-function mill-turning machine.

At the other end of the turning spectrum, the eight-tonne Multus B200W mill-turn centre will demonstrate Okuma's approach to high-end, multi-functional machining using impressive milling capability. With up to 22

kW of main spindle power and an 11 kW counter spindle for turning, the machine is also capable of performing prismatic machining operations using a milling spindle rated at 12 kW mounted on a swivelling, 225-degree B-axis.

The slant-bed lathe achieves high machining accuracy in a normal shop floor environment. Tests have shown thermal deviation to be less than 10 microns over a 24-hour period, despite a variation in ambient temperature of 8°C. This performance is a result of the application of Okuma's patented Thermo Friendly Concept to both the machine structure and the spindle, together with the use of 0.1-micron resolution linear scales in the orthogonal axes.

The machine has the added benefit of the manufacturer's OSP-P200 control, which uses an industrially hardened PC to run both the Okuma operating system and Windows XP. A feature of the control is the most comprehensive collision prediction and avoidance system currently available.

The entire machining area right out to the spindle head, slideways and guarding is monitored in real time during an automatic machining cycle or, unusually, in manual mode as well, preventing the axes being wound by hand into a collision situation.