Product category:
Control systems, DROs, etc, for machine tools
News Release from: ACI (UK) | Subject: Howard 2000
Edited by the Manufacturingtalk Editorial
Team on 23 August 2005
Toolmaker's machine runs unmanned at
night
The ability to run its vertical machining centre unmanned throughout the night is providing injection toolmaker Howard 2000 with an invaluable competitive edge.
The ability to run its vertical machining centre unmanned throughout the night is providing injection toolmaker Howard 2000 with an invaluable competitive edge, particularly against the threat from toolmakers in China Based in Birmingham and an established producer of plastic injection, aluminium, zinc and magnesium pressure diecast tools weighing up to five tonnes, as well as ceramic moulds, 12-employee Howard 2000 supplies customers from a wide range of industries throughout the UK
This article was originally published on Manufacturingtalk on 11 Dec 2007 at 8.00am (UK)
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"With all mould tool drawings now being handled electronically, and what with video conferencing and the like, it is clear that toolmakers of every size need to keep one step ahead," said director Phil Howard.
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"So, to ensure we remain competitive, we not only have to invest in the appropriate high technology but we also have to ensure we run that equipment in the most cost-efficient way".
In Phil Howard's eyes, the cost-effectiveness process starts with machine purchase since, he said, "customers nowadays want things twice as quick but would like to pay only half as much".
He continued: "When we needed to replace an ageing vertical machining centre, we looked around at what was available for our budget.
Having regular dealings with the 600 Centre (for example, we have a number of their Fanuc wire eroders) and having experienced their excellent after-sales support and back-up, it soon became clear that the level of technology and price of the Richmond 1000 on offer couldn't be ignored".
He added: "After all, vertical machining centres are all very similar, yet the Richmond was roughly half the cost of all other comparable machines we looked at and it lacked nothing in terms of build quality and features.
We felt it really set a new standard in performance to price ratio".
With 560 mm in both Y and Z axes, a large 625 mm throat coupled with a table length by width of 1020mm by 510mm, the Richmond 1000 has a positioning accuracy of +0.005mm and a repeatability of 0.0025mm - characteristics of a rigid build quality complemented by a 15mm thick Meehanite cast base that has been annealed and stress relieved.
INA ballscrews and NSK spindle bearings also feature along with THK linear ways.
In particular, says Phil Howard, the machine's spindle flood coolant facility is especially highlighted as very useful when machining graphite electrodes (copper electrodes are also regularly produced on the Richmond).
One aspect of the machine did, however, initially create some cause for concern but, in the event, the Richmond's Anilam 6000 Series control, from ACI (UK), has 'worked wonderfully', said Howard.
"This was our first Anilam CNC (although we do have an ACI Acu-Rite DRO on a bed mill), because until now we have standardised on our machining centre control technology.
But as soon as we were taken through the 6000 Series' user friendly, easy-to-use programming routines - and saw the real capabilities of the system, particularly in terms of its look ahead functionality - we were confident that the control wouldn't be a problem".
Processing a lot of tools that incorporate three-dimensional features means that machining programs are large - generated via CAD/CAM and drip-fed to the machines - yet the Anilam system has accommodated these with 'no worries', said Howard.
"There's not been any 'stutters' and the blends are perfect".
With the control's networking capability featuring auto-sensing at 100 Mbit per second for data transmission, the result is fast program verification and processing of 8,000-block programs featuring 0.003in step-over increments.
"In addition," said Howard, "We've set up the Richmond in the same way as our other vertical machining centre and, having had certain Anilam programming codes altered to suit our way of working (such as those relating to the machine's 20-tool toolchanger), we can confidently produce same-job male and female moulds on separate machines with no hiccups".
The Anilam 6000 Series combines ACI's renowned conversational 'Machinist' language programming routines with G-Code programming on a digital platform.
In addition to advanced production cycles, the control boasts an enhanced mould and die capability with scaling, mirror image, model corner rounding and chamfering as well as a host of canned cycles including mould rotation and draft angle - ideal for Howard 2000's workload.
Interactive CAM programming using icons is standard with menu driven tooling, compensation and interface checking through the in-built processor.
The canned cycles also include: Irregular pockets - a simple routine of prompts produces clearances of irregular shapes; Geometry - the geometry calculator, for determining points, lines and circles, automatically forms the program foundation; and bolt hole pattern and drill cycles are created by simple question and answer routines.
Simulation graphics embrace rapids, feeds and colour differentiated compensated moves, isometric views, autopart fit and window zooming along with static tool display.
Through Anilam's Integrated Programmable Intelligence all drives are now housed in one compact module for easier service.
In addition, tool and workpiece probing cycles are standard and, again, are easy to use through a graphical/conversational screen.
After a cycle is selected, the appropriate variables are input via simple question and answer routines.
The tool measurement cycles include: Tool probe calibration; Tool length and diameter offset preset; Manual tool length and diameter measurement (for special tools); and Tool breakage, length and diameter wear detection.
The workpiece measurement cycles embrace: Edge find - single surface measure/edge; Corner out/in - outside/inside part corner find; In/out boss - inside/outside hole or boss find; In/out web - inside/outside web or slot find; Probe move - protected positioning; and Skew comp - skew error compensation or angle find.
Armed with such a powerful control-machining capability, Howard 2000 regularly runs the Richmond unmanned overnight and at weekends, depending on workload, and generally uses 1mm or 2mm ball nose cutters for finishing routines with an operator present.
"To stay in business today you have to work smart and fast," concluded Howard.
"The technology we use allows us to do just that.".
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