Product category:
Large milling and boring machines (over 2000mm in X)
News Release from: Cincinnati Machine | Subject: Large bed vertical machining centre
Edited by the Manufacturingtalk Editorial
Team on 28 February 2006
Large bed VMC cuts door machining time
by fifth
Since the introduction of a large bed VMC, processing time for aerospace door linings has been reduced from 15h to under 12h - a significant saving when manufacturing up to 20 door linings/month.
When Techni Grind Machining (TGM) of Preston needed a large bed vertical machining centre for a new project it was undertaking - the company immediately turned to Cincinnati and its FTV1040-3700 model When the aerospace subcontractor was awarded a project to manufacture 1200mm by 800mm cargo door linings for the Airbus A340 aircraft, it found no machine tool manufacturer could compete with the bed size and machine capabilities of the Cincinnati FTV1040-3700
This article was originally published on Manufacturingtalk on 12 Mar 2003 at 8.00am (UK)
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TGM initially machined the door linings on an alternate machining centre and despite it being a powerful machine with a large bed it was insufficient for the continual batch quantities required.
Since the introduction of the Cincinnati FTV1040-3700, the processing time has been reduced from 15h to less than 12h.
When manufacturing batches of up to 20 door linings a month, this has proven to be a significant saving.
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The introduction of the 3.7m bed Cincinnati FTV has been a revelation to six year old TGM, as manufacturing engineer Dennis Boyle commented: "The Cincinnati has slashed machining times considerably already.
We have not really pushed the machine yet, and it has taken three hours off cycle times, improved tool life, surface finish, set-ups and swarf removal - absolutely amazing." One issue TGM had with previous machines was loading the 300mm deep, 1200mm by 800mm billets with the fork lift truck.
The spacious work area of the FTV now enables a truck to manoeuvre the workpieces into the work area without manual lifting.
This prevents any damage to the billet, machine and most importantly the operator.
The large bed of the FTV1040-3700 has enabled TGM to manufacture two aluminium sub plates to fix all jobs on the machine bed with simplicity.
This has reduced set-up times by eliminating the need to clamp the corners of workpieces.
Clamping is now via air vacuum.
This combined with the exceptional travel of the three axes allows TGM to machine over all sides of the workpiece in one set-up.
As Boyle continued: "The two plates would not fit on any other machine; we can now machine all jobs in just two set-ups.
The Cincinnati was also supplied with an optional partition in middle of the table to make the FTV a dual load machine, when we start using this our processing times will be cut even further." The rigid construction of the FTV1040-3700 is well suited to the nature of work conducted at the 17 employee company.
Alternate machines at TGM would chatter and make howling noises during machining, whilst the robust FTV takes bigger and better cuts utilising the powerful Fanuc motors and Fanuc 18i-MB controller.
Boyle said: "The machine has a BT40 spindle that selects a 100mm face mill cutter from the 48 tool carousel.
This roughs out titanium and aluminium at 3000 to 4000 rev/min with absolutely no problems credit to the high torque spindle.
We are cutting with such ferocity that the swarf bin is emptied every 25 minutes." The high torque spindle matched with the robust nature of the FTV guarantees better loads on cutters.
The vibration on the Cincinnati FTV has decreased to such an extent it has visibly improved tool life.
This is even more evident on deep jobs that require the cutter and column to demonstrate increased stability.
This has improved accuracy, surface finish and reduced tooling changeover times tenfold.
It has also reduced machining mis-matches and improved cycle times due to fewer interruptions to the machining process.
To machine at high metal removal rates, rigidity is paramount and Cincinnati has taken this into consideration with machine design.
The leadscrew of the FTV does not move; the nut linking the leadscrew and machine column spins to prevent machine deflection.
This in turn increases accuracy, rigidity and repeatability whilst enhancing tool life and surface finishes.
Machining such vast amounts of material requires an exceptional swarf conveyor, especially when the machine is running 24h/day.
To support this, Cincinnati has installed an extremely large swarf conveyor on the FTV1040-3700.
This removes the swarf immediately from the machining area and directly to an easily accessible swarf bin.
""The Cincinnati machine has been outstanding since its introduction in October 2005".
"Any jobs up to 2m were taking their toll on our other machines and they were becoming tired - the FTV is built to last and it will run all day," concluded Boyle.
TGM director Steve Holmes said: "We work with companies such as BAE Systems, Gardner Aerospace and Airbus conducting military and civil work.
We work to the highest standards and are certified to supply all our customers as well as ISO:9001 accredited.
We have invested over GBP 1m in just over a year to stay at the forefront of our industry.
The Cincinnati FTV has been an exceptional buy and it is already proving its worth.
The well presented staff at Cincinnati have been very helpful and the service is superb.
In essence they have given us a high quality product and service that we are very pleased with." * About Cincinnati Machine - Cincinnati Machine designs, builds and sources high-precision machine tools for the global aerospace, automotive, mould and die, medical and general machining markets.
The company offers technology-driven solutions that include 3-, 4- and 5-axis CNC horizontal and vertical machining centres; and vertical, horizontal and multi-axis turning centres.
Cincinnati Machine in Birmingham, UK, is a manufacturing plant and a focus factory for the design, manufacture, sales and marketing of the Blue Technologies ranges of machine tools.
Blue Technologies is a division of MAG Industrial Automation Systems, headquartered in Michigan, USA.
Other divisions within MAG IAS include Cincinnati Technologies, serving the OEM and Tier 1 aerospace market; Powertrain Technologies, serving the global automotive market with customised high-production solutions; and Maintenance Technologies, responsible for the global after-sales and service parts market for all MAG IAS customers.
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