Subcontractor holds tolerances of 20 micron on all CNC machines and the 100th part off is exactly the same as the first - a degree of accuracy and repeatability not possible using manual machines

There can be few companies that have embraced CNC machining so quickly and enthusiastically as S and E Engineering. The family-run UK subcontractor installed its first computer-controlled machine tool in 2005 and by January 2007 had invested in four vertical machining centres and three CNC lathes - all from Hurco.

Martin Sanderson started the Scunthorpe company in 1988 with a GBP 10,000 bank loan, at which time he had a mortgage and a family to support.

The first month's turnover was GBP 48, which focussed his mind on swiftly increasing the level and profitability of his business.

This he did, and by 2005 he owned an impressive array of manually operated machines including large horizontal and vertical borers, three centre lathes, one of which can turn parts up to four metres long, and a number of smaller machines.

There has always been an emphasis at SandE Engineering on machining of larger workpieces, which sets the subcontractor apart from many of its competitors.

Once he started to invest in CNC machines, Sanderson decided to maintain his capability to provide large-capacity milling by installing two Hurco VMX64s, which have working volumes of 1625 x 860 x 760mm and can accommodate nearly three tonnes on the tables.
Two smaller VMX42s provide 1066 x 610 x 610mm machining capacity for components weighing up to 1,360kg.

There were compelling reasons for S and E Engineering to invest in CNC machine tools.

Potential customers were saying that they would not allow non-CNC plant to be used to machine their parts.

Some work for which the subcontractor was asked to quote could not practically be produced on a manual machine to the required tolerances.

Then one customer supplying repair equipment to the offshore industry suggested that more work would be forthcoming if a machining centre were to be installed, although there was no guarantee.

Sanderson duly bought the first VMX42, which rapidly reached capacity based on his firm's 7.00 am to 5.00 pm shift pattern.

So it has been with all of the other Hurco machining centres, which have hardly stopped from the time they were installed.

Where possible the machining centres, particularly the larger models, are left unattended to cut a part into an evening 'ghost' shift.

The second CNC machine on site was one of the lathes - a 254mm chuck model designated TM10 - followed by another identical machine and a smaller 203mm-chuck TM8.

The idea was to migrate the benefits that resulted from the first machining centre across to the turning department, in the first instance for batch production of steel components.

Sanderson's brother, Jamie, is responsible for running the turning cell and despite having had no previous programming experience, was conversant with generating programs using the Hurco Max controls after just two days' training.

Previously, his time was spent looking after one manual lathe.

Commented machine shop manager, Jim Swan, brother-in-law to the Sandersons, 'We routinely hold tolerances of 20 micron on all of our Hurco machines and the 100th part off is exactly the same as the first - a degree of accuracy and repeatability that is not possible using manual machine tools.' He said: 'The other major benefit is that labour cost per machine is around one third of what it used to be for a given output, so we have been able to freeze the prices we charge customers to compete more effectively in a global marketplace and still make a profit.' All programs are input on the shop floor using Hurco's conversational Ultimax or Max control systems, which S and E Engineering staff find easy to use and ideal for small batch work and even one-offs, as are frequently ordered by customers working in sub-sea and highway maintenance.

In this connection, bearing in mind that the company is new to CNC, Hurco's telephone back-up has been very helpful when the occasional programming problem has been encountered.

The decision to opt for Hurco machines hinged on the capability of the controls, coupled with the high residual value of the equipment, as confirmed by the firm that provided the finance, Hitachi Capital.

Martin Sanderson intends to keep the CNC lathes and machining centres for five years before part exchanging what will be relatively lightly used machines for new models.

On that basis, he will enjoy three and a half years of 'free' use of the lathes after they have been amortised and at least two years' machining centre operation after the finance periods have ended.

Having to increase its manufacturing capacity, a subcontractor has invested GBP 250,000 in CNC lathes and a vertical machining centre to meet growing oil/gas/subsea components demand

Having to increase its manufacturing and size machining capacity, a subcontractor has invested GBP 250,000 in CNC lathes and a vertical machining centre to meet growing oil/gas/subsea components demand. Investing more than GBP 250,000 in a package of Colchester-Harrison CNC machine tools from 600 Centre of Shepshed, subcontract precision machinist Ultimate Precision of Jarrow, Tyne and Wear sees the purchase of five machines as important in increasing its capacity to cope with 60 to 70% increases in production demands from oil and gas and subsea sectors.
The order, involving progressive installation of a Colchester-Harrison Combi 6000, MultiTurn 4000 and 2000 flat-bed CNC lathes, a Tornado T8, two-axis lathe and a Storm VMC 1300 vertical machining centre, is part of the company's planned increase from small to medium size part machining into high specification parts up to 1m cube and up to 1m diameter by 4m long.

The company, under managing director Ken Davidson, employs 30 people and has grown from its formation in 1997 supplying aerospace, automotive, medical and general engineering sectors.

It has recently added 55% to its turnover from contracts gained from subsea and offshore industry customers.

Said sales and marketing manager Andy Hey: 'We still produce batch work for existing customers and continuous production for the automotive sector, which tends to have very tight margins, but the new areas are really very challenging in materials, tolerances and machining knowledge so we need production equipment that is reliable, accurate and very flexible.' The company investigated the machines available and while managing the growth of the business, value for money against equipment performance and flexibility were key markers on the comparison spread sheets.

'Here,' said Hey, 'The performance of the Combi and its specification fitted our requirements exactly against machines costing 45% more.
We also have the factory in Heckmondwike, West Yorkshire providing a close lifeline for support because our philosophy is not to let customers down on delivery.' In addition to general materials, Ultimate Precision also produces parts from exotic materials and bespoke alloys, such as Duplex and Super Duplex, stainless steels and ceramics.

Tolerances run into a few microns on certain dimensions and high orders of surface finish are commonplace.

Here programming was a key element in judging the flexibility ranking of the machines and by standardising on Fanuc control, which is a key part of the 600 Group machine's specifications, means the setters on the shopfloor are quick to adapt to the new installations.

In addition to the machines from 600 Centre, the company has installed Fanuc's FAPT off-line programming and made good use of the on-machine interfaces and macros developed by Colchester-Harrison.

Altogether, the CNC plant list at Ultimate Precision has 21 machines and three co-ordinate measuring machines.

DMG plans to show six new machines at the forthcoming EMO machine tool exhibition, including universal, vertical, twin-spindle, mill/turn centres, sliding head and multi-spindle types

German machine tool group, DMG, plans to show 68 machine tools under power. Man will feature the latest high speed linear drive technology that has been well accepted for high dynamics and wear-free axis movement. The extensive range will be represented in Hall 2, Stand A01 at the EMO 2007 exhibition in Hannover (September 17-22).

Out of this vast technology showcase, 15 machines will be world launches on the 3,900m2 stand, some 10% larger than the same event in 2005 and will also feature support from CADCAM, control system and financial advisors as well as service, product support and tool management displays.

From the DMG turning range, six new machines will be launched out of 30 installations including universal, vertical, twin-spindle, mill/turn centres, sliding head and multi-spindle types.

These will be complemented by 31 machining centres of which nine will be new including 5-axis universal, vertical, travelling column and horizontal configurations.

In addition, examples of more specialised Ultrasonic and Lasertec machine ranges will be shown.

These machines are widely used in the medical, toolmaking, semiconductor and optical sectors.

One of the breakthrough areas in ultrasonic production technology for DMG is the complete machining of brake discs made from fibre-reinforced ceramic materials.

Meanwhile for Lasertec, the precision boring of funnel-shaped air cooling holes in turbines and aerospace components has considerably improved performance efficiency and fuel consumption.

CAMTEK Pacific has released a PEPS NC/CNC Programming CAD/CAM system capable of automatic multiside and multipart programming.

PEPS Mill Expert eliminates the need for programming NC/CNC Milling Machining Centers. NC machine is instructed to produce a part without a single line of the part program being written by the user.

To produce a part all that is required is to describe features (pockets, holes, slots etc) that constitute the part and to identify their location. Using this information and the company's ‘know-how’ and Tool/Cut Database, the system resolves all machining operations involved, sorts them out in the optimum sequence and generates, in seconds, a comprehensive part program for the part as a whole ready to go for unmanned NC machining.

Multipart Mill Expert allows loading of pre-programmed parts on a multisided pallet or on a table and to merge all operations of all parts into one NC program to machine all parts as a whole.

All operations are sequenced and grouped automatically by Mill Expert to provide machining accordingly to the machining stage, for example, roughing, semifinish, finish, and trimming.

If a tool change optimisation is activated, all operations to be performed at the same stage by the same tool are grouped together.

Parts can be machined from different sides and any parts can be placed on any pallet side.

The layout of parts can be easily modified, parts can be replaced, added or removed as required.

All machining is done using the same subroutines for all instances of the same feature.

The system is employed by D.J.Batchen Pty Ltd to achieve non-stop machining on its new two pallet horizontal machining centre, Kitamura HX400. CNC Engineering Sales and Service provided an integral solution by supplying the machine tool, tooling and fixtures.

"CAD/CAM vendors have been asked by manufacturing companies for a long time to provide efficient NC programming of the layout of various parts on a pallet or on a table,” said Camtek Pacific managing director, Mark Goldfeld. “We are proud that we, an Australian company, are the first to make it possible".