Product category:
Motor sports manufacturing: machining, software, CAM
News Release from: DMG (UK) | Subject: Deckel Maho DMU 50 eVolution five axis M-Cs
Edited by the Manufacturingtalk Editorial
Team on 03 December 2002
Two five-axis M-Cs provide total
flexibility
The addition of two five axis machining centres to its manufacturing resources has revolutionised machining practice at Formula One racing team Jaguar Racing, Milton Keynes.
The addition of two Deckel Maho DMU 50 eVolution five axis machining centres to its manufacturing resources has revolutionised machining practice at Formula One racing team Jaguar Racing, Milton Keynes "The machines were bought in for their total flexibility and have provided just that," according to Jaguar production manager Graham Saunders
This article was originally published on Manufacturingtalk on 21 Jun 2001 at 8.00am (UK)
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"The eVolutions allow us to approach jobs in a completely different manner as compared to machining on a basic three axis machining centre." Mr Saunders commented.
"The most complex component that we produce is the main hydraulic manifold for the clutch, gear change and differential system on the cars.
It incorporates a number of holes, bores and other features situated at compound angles.
Whereas its predecessor was machined in five set-ups on two different machines and required specialised fixtures, the DMG machines enable us to completely machine it in two eight hour set-ups using basic clamping arrangements." Ford Motor Company-owned Jaguar Racing has enjoyed modest success with the Jaguar R3 during the 2002 FIA Formula One World Championship.
The team finished seventh in the constructor's championship and driver Eddie Irvine finished ninth in the drivers' championship - including third position in the Italian Grand Prix at Monza.
Efforts are now focussed on developing the new Jaguar R4 to maintain the momentum of improving performances, built up during the second half of the year.
The two DMU 50 eVolutions will have a role to play in this, as Saunders explained.
"Although we've had five axis machines for some time their main function was/is to machine patterns and moulds for chassis and body components.
Our main prismatic machining resources were good quality basic three axis machining centres.
This undoubtedly restricted our machining capabilities; on the manifolds there were some tasks that used to be completed manually, for instance." The two Deckel Maho machines were purchased as part of an upgrade program machining facilities at Milton Keynes.
When considering potential suppliers, Saunders was looking beyond the immediate requirement.
"DMG have a vast range of machines complemented by an equally wide range of options so it becomes possible to customise the machining package to suit our requirements.
They also represent very good value for money when compared with the alternatives." Flexibility of configuration is evidenced in Jaguar Racing's two DMU 50 eVolutions.
Both are full five axis versions of the machine and each has the 18000 rev/min HSK 63 spindle with through-tool coolant and programmable coolant nozzles, plus workpiece probing facilities to assist set-up.
However one machine has 90 tools whereas the other has 60.
On the 90-tool machine, Jaguar Racing took up the option of having a removable tailstock arrangement on the table.
The 90-tool machine has contact-type tool probing whilst the 60-tool machine has laser probing.
"We need 85 tools to machine the manifold block so that dictated the magazine size for one machine." Saunders remarked.
"However the larger magazine takes up a lot of extra space and most other components can be machined with less than 60 tools." Jaguar Racing's machining requirements have to be considered against a background of small batch quantities and regular design modifications.
Manifolds, for instance, are produced in batches of 15 and one batch is likely to last for an entire season and few components are machined in batch quantities greater than 20-off.
All components are machined from solid bar or billet - the shop routinely processes aluminium alloy, titanium and stainless steel - so stock removal requirements are high, as is the need for accuracy.
The tailstock attachment for the 90-tool machine is used to assist machining of 'spindly' components from round bar.
An example of this is the barge-board stays which support the aerodynamic panels attached to the sides of the car.
These were formerly fabricated from two turned ends, each of which had a machined rebate to support the separately produced aerofoil-section centre section; this was welded into place.
Jaguar Racing now produces these from solid titanium bar which is supported between centres on the DMU 50, utilising combined rotary and linear movement of the table and spindle axes to create a much stronger component in one seamless operation.
Malcolm Watson creates most of the programs used on the machines, using Unigraphics CAD/CAM software from EDS in combination with two alternative post processors.
One of these uses the Heidenhain tilt working plane whereas the other uses tool centre point management (TCPM).
He comments.
"We operate in a small batch toolroom-type environment so we aim for safe operation to minimise the risk of collisions resulting in scrap parts and the consequent delay in availability.
For instance we would always retract the spindle to eliminate the possibility of collision prior to table repositioning.
That said, the speed of rapid axis movement (50m/min) on the DMU 50 eVolutions means that we lose very little time.
"From a capability standpoint the five-axis capability has widened the limits on our ability to machine and this has obviously gone down well with our designers.
Even so, set-up is as straightforward as it would be on a three-axis machine though individual part programs do take longer to produce as there is much more content to them.
So far as machining performance is concerned the machines are very hard to find fault with.
The Heidenhain CNC control's contouring performance is very good so we get nice clean blends.
Likewise the machines' rigidity is good so surface finish is excellent." Graham Saunders concluded.
"Machine reliability has been excellent in all respects.
Once set up we're very happy to leave the machines to get on with the job which frees our machinists for other tasks.
The only shortcoming that relates to the machines is that we only have two of them, though it is highly likely that additional five axis capacity will be sourced from DMG in the future.".
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