Turning small parts on a large lathe usually is not the most efficient use of a company’s assets, and actually may have an adverse effect on the bottom line. The SL-10 CNC lathe from Haas Automation provides an economical solution for small parts turning in a compact package that is loaded with full-size features. The SL-10 takes up only 2m x 1.5m of floor space, yet provides a generous 255mm turning diameter, 355mm turning length and a 415mm swing over the front apron.

This compact machine is a valuable addition to any shop needing a ’second-op’ machine, or wanting to add a lathe where space is at a premium.

It is also the perfect lathe for start-up shops, or as a first step into CNC turning.

The SL-10 comes standard with a 160mm hydraulic chuck and a 10-position bolt-on tool turret.

A 5.6kW vector drive spindle provides speeds to 6,000 rev/min for high surface feedrates, and an A2-5 spindle nose accepts bar stock up to 45mm.

A host of high-productivity options, such as a tool presetter, parts catcher, automatic chip auger and tailstock, are available for the SL-10 to further boost productivity, and the Haas Servo Bar 300 intelligent bar feeder may be added for unattended operation.

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.

Changing chuck jaws on a CNC (computer numerical control) lathe should take one minute, not twenty or thirty.

Many companies will spend enormous amounts of time investigating the purchase of a new CNC lathe and yet pay little or no attention to the necessary accessories–especially chuck selection. This is well illustrated by a survey taken about two years ago that revealed the vast majority of the CNC lathes sold in the U.S. were purchased with traditional, slow, jaw changeover systems.

Today, many astute buyers are ordering CNC lathes with quick-change tooling systems. They will reduce tool changeover downtime by several minutes. These buyers also will often purchase a machine whose CNC allows them to program, edit, and load a new part program at the machine while the last part of the current run is being machined. Again, several minutes of program changeover downtime are eliminated. But, in chuck selection, many of these same buyers will select a power-operated chuck that gives them quick, consistent clamping action and force, and reduces operator fatigue, but it is still a chuck that requires 20-30 minutes for jaw adjustment or jaw change and another 20-30 minutes for reboring soft jaws.

How Long?

When the average shop owner, foreman, or manufacturing engineer is asked how long it takes to adjust or change chuck jaws or rebore soft jaws, most admit that they really don’t know. They lump lathe changeover into one overall figure that usually falls in the 45 to 90 minute range.

Since it was in our best interest to find the actual times for these tasks, here’s what we determined: When using power-operated chucks that incorporate jaws fastened with screws, it takes about twenty minutes to adjust or change jaws–sometimes even longer if the operator lacks skill or motivation.

An SMW KNCS model chuck, shows how jaws can be adjusted or changed in one minute or less. And, it must be pointed out that there are other chucks on the market that can do the same thing. With chucks of this type, soft jaws do not require reboring. The same set of soft jaws can be remounted and reused over and over again. Eliminating the need to rebore saves from 20-30 minutes or more depending on the operator’s ability.

In cases where changeover takes place twice per shift, and this is the norm in today’s world of just-in-time short runs, use of this type of chuck saves an average of 1.4 hours of chuck changeover downtime per shift. When combined with one of today’s quick-change tooling systems and advanced CNC control, machine changeover can be accomplished in less than 10 minutes.

One-Minute Jaw Change

The new type of chuck allows jaws to be changed or adjusted in one-minute or less because the jaws are not fastened with screws. Either one-piece jaws or top-jaw master-jaw combinations are retained in the chuck by confining the jaws in radial tee slots and actuating the jaws through precision ground serrated teeth in the bottom of the jaws

To change jaws on this chuck, the operator simply inserts a specially designed hex key into a socket near each jaw, turns the key one-quarter turn clockwise which releases the jaw, removes the jaw, inserts the new jaw, and turns the key one quarter turn counter-clockwise to engage the new jaw and lock it into position. The hex key is specially designed so that it cannot be removed from the socket until it is turned back (counter-clockwise) to its original position. This insures that the new jaw is securely locked into position and eliminates the potentially dangerous possibility of the new jaw flying free when the spindle rotation starts.

How jaws can be readjusted in less than one-minute, using the same hex key operating sequence. This type chuck also allows using the same set of hard jaws to cover a wide range of work diameters because it engages different sets of teeth on the bottom of the same jaw. This feature reduces the number of hard jaws required to cover the full clamping range of the chuck. As an example, one company produces over 700 different parts using only eight sets of hard jaws.

Reboring Eliminated

The accuracy of the jaw actuating system and jaw mounting system in most chucks is insufficient to produce acceptable low levels of runout in the remounted jaws. This is the primary reason for reboring.

In the case of the new style chuck, the jaw mounting and actuating systems hold remounted jaw runout down to as little as 0.0002 inch. For example, a user can remount a set of soft jaws that were originally bored to 2.5000-inch diameter to run that same diameter again without the need to readjust and rebore them. Many users of this type chuck, bore sets of soft jaws to accommodate their most frequently used clamping diameters and actually use the same set of jaws to clamp otherwise different parts on their common diameters.

Other Advantages

Power-operated chucks of this type also offer several advantages beyond changeover downtime reduction. One advantage is the two-level (high-low) clamping force within the same machining cycle. This means that a high level jaw clamping force can be applied during a roughing operation and automatically changed to a lower level for precision finishing. This change can be preset and initiated by a NC part program "M" function without releasing the workpiece, thus maintaining concentricity.

Another advantage is the compact design of this type chuck which reduces the amount of jaw overhang. This, in turn, permits heavier clamping forces for heavy roughing operations, and in all cases improves part accuracy by minimizing jaw deflection.

Admittedly, chucks of this advanced type are not inexpensive. But when the time savings are carefully analyzed, the cost concern usually evaporates. In most situations, these chucks pay for themselves in less than six months.

UK CNC machine tool company has developed close associations with autosport suppliers and teams in aiding them to making manufacturing lead times as short as possible.

Yamazaki Mazak UK, the world's largest manufacturer of Computer Numerical Controlled (CNC) metalcutting machine tools, has developed extremely strong links with the autosport engineering industry. This reflects its long-standing status as official supplier of CNC lathes and machining centres to Formula One's Team McLaren Mercedes and its support for the numerous sub-suppliers to the many facets of the autosport sector. The machine tools available from Yamazaki Mazak are at the pinnacle of manufacturing technology and, irrespective of component type or company size, the Worcester-based company has a machine to suit most metalcutting applications.

These range from entry level 2-axis Nexus lathes through to multi-function/multi-axis Integrex machines, which will deliver productivity improvements even on the smallest batch sizes.

The extensive autosport related customer base of Yamazaki Mazak UK supplies components to competitors from clubman level to Formula One.

The common denominator with all of these customers is that they are able to rely, not only on the machine tool but also on the technology and engineering support provided by Yamazaki Mazak UK.

Given the demands placed on suppliers to the racing teams, whereby components have to be delivered in short lead times to the highest standards of consistency and quality, the knowledge that the world's largest manufacturer of machine tools is supporting those efforts makes the machine tool purchasing decision a much easier one.

The engineering support provided by Yamazaki Mazak is the key to reducing lead times for all of its customers, irrespective of industry sector.

However, in developing its Done in One strategy Mazak is eliminating much of the expense of set-up, work in progress and the number of machine tools required.

Fifteen new high technology machine tools supplied by Worcesterbased Yamazaki Mazak U.K. are playing a major role inmanufacturing high precision components for the Team McLarenMercedes MP4-19 race car currently competing in the FIA Formula 1World Championship. Badgeworth Drive, Worcester based Mazak hasbeen the official machine tool supplier to the team since 1997when their machining and turning centres were installed inMcLaren Racing's machine shop in Woking.

Now, with theMcLaren Group having re-located to its state-of-the-art McLarenTechnology Centre, 15 new Mazak machines are engaged around theclock in manufacturing precision components for gearboxes,steering assemblies, suspensions and transmissions for the latest225mph race car.

The strength of the relationship between thesetwo leading technology based organisations is such that at MACH2004, alongside the nine Mazak machine tools on show was a TeamMcLaren Mercedes Formula 1 racing car.

The latest Mazak 5-axis,multi-function machine tools in operation at the high technologymachine shop are capable of machining high precision componentsfrom castings or metal billets in a single operation, resultingin significantly faster turn-around's in the high pressureworld of Grand Prix racing.

The machine shop where the Mazakmachine tools operate has a constant temperature control.

All themachine tools and ancillary equipment such as tool cabinets arecolour co-ordinated.

Even the tiled floor is off-white,presenting a striking contrast to the 'typical' imageof a machine shop.

'Speed of response alongside the veryhighest standards of precision are all important in Formula 1 andMcLaren's decision to work with Mazak says a lot for thequality and reliability of our machine tools,' explains TonySaunders, sales director for Yamazaki Mazak U.K.

'In manyrespects our machine tools are at the cutting edge of technologyand it is a great compliment that a world class organisation suchas McLaren feels we meet their tremendously exactingstandards,' he adds.

'Parts for Formula 1 racing carsare increasingly complex in shape and the latest Mazak 5-axismachine tools lend themselves perfectly to manufacturingcomponents of this nature.' Team McLaren Mercedes'Formula 1 racing cars are next in action on Sunday 25th Aprilwhen they race in the first European leg of the Formula Onecalendar at the Imola circuit in San Marino, Italy.

Team McLarenMercedes Kimi Raikkonen, who finished second at Imola lastseason, will be looking to go one better at what is considered tobe Ferrari's 'home' circuit.

1) Mazak is theworld's foremost designer and manufacturer of machine tools.In Worcester - where it employs 400 personnel - Mazak operatesits european manufacturing facility as well as its UK sales andservice operations.

There are also manufacturing facilities inJapan, the USA, China and Singapore in addition to an extensiveworldwide sales, distribution, service and support network.

2)About McLaren: McLaren Racing, the company behind the TeamMcLaren Mercedes Formula One team, was formed in September 1980as a result of a merger between Team McLaren and Project Four; aBritish company owned by Ron Dennis, now Chairman and C.E.O.

ofthe McLaren Group.

McLaren has won eleven Formula One WorldDrivers' Championships - including the 1998 and 1999 WorldDrivers' Championships - and eight Formula One WorldConstructors' Championships.

A vital tool to help the team produce parts for its F1 cars under the intense time-to-market pressures is a suite of manufacturing software that is easy to use on the shopfloor.

Licom AlphaCAM manufacturing software has been selected by Jordan F1 as a vital tool to help the team produce parts for its cars under the intense time-to-market pressures of Grand Prix Motor racing. With races taking place in a different country every fortnight during the season, race cars normally arrive back at the Jordan factory in Silverstone on the Tuesday following an event - only to be required on track for the next round of the World Championship eight days later! 'Here at Jordan Grand Prix we subcontract out a lot of our component work. But while our planning department, production department and quality assurance department ensure that best practices are carried out at each of the companies we use, the design criteria originates from here,' states Jordan's Trevor LeCoche.

'Designers today must be more conversant and have an appreciation for what the modern machine tool can do.

Some of the parts used today simply could not have been made a few years ago.

But with surfacing technology as advanced as it is, the options are greater.

'All CAD designs, regardless of its destination, originate in 3D on the SRDC-Ideas platform and up until 1999, we used it here in the CAM office.

However, we found that we had very little cause for 3D work and it didn't lend itself to the majority of work we were doing.

As a result, we sought to purchase a system that had a shopfloor programming facility.

There were a lot of good systems on market, but it was the ease of use that sold me on Licom's AlphaCAM system.

The last thing we need when a last minute component modification is called for is to have to spend hours on an Einstein-like CAM programme.

'We installed 2D and 21/2D systems running on Hewlett Packards here in the machine shop for profiling work on a range of lathes and a Bridgeport VMC 560 mill.

If we need to do any 3D surfacing work, we will use the Ideas programme - the two are very compatible.

Typically, we are called on to do jigs, rear wing end plates, first offs and modifications required on the car.

Currently, we are working on modifications to the floor ballast, to find the optimum position for the engine in relation to a number of race conditions.

The key factor is that we must be able to react quickly to any given situation.

And for that, we must have reliable functionality and ease of use.' 'We have since added a another seat in our composites department, where everything is taken straight from the digitiser,' adds LeCoche.

'We are simply cutting 2D profiles on a Zund cutter and using AlphaCAM for its nesting capabilities.' 'The growth of a Formula 1 team is all dependent on sponsors and likewise, the size and capabilities of a machine shop.

To that end, I would hope we would be able to expand our operation in the future and bring certain aspects of the subcontract work in-house.

When Stainless Metalcraft won a new contract to produce cryogenic vessels for a customer in Switzerland, it not only needed to develop the appropriate manufacturing processes within super fast timescales, but it also had to quickly install the appropriate machining capacity. The answer was a Soraluce FP8000 travelling column, floor-type milling machine from Ward CNC. The fabricated vessels, which are used for particle acceleration, also contain various tubes, forgings, castings and other items.

These components are 'prepped' machined by Stainless Metalcraft before being welded by the company into the finished fabricated structures.

Knowing there were few machines that could provide the required bed capacity to accommodate the 5200mm long by 550mm diameter vessels, and having seen the Soraluce at MACH 2000, Stainless Metalcraft's project manager John Tadman recognised that the machine's 8000mm X axis would comfortably accommodate the large workpieces.

He also saw how the machine's 28kW spindle motor - and its Y and Z axes travels of 2000mm and 1200mm, respectively - coupled with the use of Soraluce's 4,000 revs/min universal head, would result in the most cost-effective machining of the stainless steel vessels.

'Equally importantly,' he says, 'because the machine was available ex-stock, we were able to have it delivered with minimal lead time direct from Ward CNC's Sheffield showroom.' Adding that the universal head is a particular asset, John Tadman highlights the production benefits of utilising its 2.5 degree incremental positioning in both vertical and horizontal planes.

'Also, we subsequently purchased an indexing table - a fourth axis - as well as non-contact Renishaw job probing, to further extend the machine's capabilities,' he comments, 'and Ward CNC's integration of these was impeccable.' Developed under the auspices of the Danobat Group's IDEKO research and development facility in Spain, the Soraluce FP8000 features high-quality build for unmatched heavy-duty milling performance, with its characteristic stability and rigidity being based on heavy-duty cast iron construction.

Two years on and John Tadman's confidence in the machine has been justified, he says, 'since it has lived up to expectations in every department'.

So much so that Stainless Metalcraft is this year looking to purchase another, larger capacity Soraluce from Ward CNC to replace existing equipment at its site in Chatteris, Cambridgeshire.

This will complement an already impressive plant list that includes a Ward CNC-supplied Toshulin vertical turning and boring machine that was recently installed to give increased machining capacity.