DMG production cell helps produce complex housings

DMG (UK) has revealed how a three-machine production cell with 24-pallet robotic loading is helping Manthorpe Engineering produce a range of complex aluminium, steel and titanium bearing housings.

The flexible cell, engineered by DMG (UK) will provide automated production of 10 types of housings in on-demand sequence for a new generation of aircraft engines due to go into production in 2011.

The system is built around two of the latest Deckel Maho DMU 70 Evo linear, five-axis machining centres and a Gildemeister CTX 520 linear multi-axis, turn-mill centre.

The machines, set-up and inspection stations and pallet storage will be serviced by an Erowa ERS five-axis robot with 24 pallets each 600mm square, that run on linear rails between the machines for loading and unloading against fully automated production planning and scheduling instructions.

DMG (UK) said that once installed, the cell will represent a complete 'production reversal' for Manthorpe Engineering, extending it from its 'niche' machining business of producing ultra-complex, high value aerospace and power generation parts in very difficult to machine materials up to 3m in diameter into larger quantities of smaller but still high value components.

Sitting prominently on the shopfloor is a five-axis Deckel Maho gantry design machining centre with vertical cross beams.

The DMG (UK)-supplied DMU 340 FD is worth over GBP1.3 million and is able to combine milling with turning operations on parts having a diameter of 3.3m and weighing up to seven tonnes.

The machining envelope is a massive 2.8m x 3.4m x 1.6m to which its SK50 taper spindle can be positioned at a rapid traverse rate of 60m/min in X, 30m/min in Y and 40m/min in Z.

The 44kW power-spindle, specified as a 5X Torquemaster, is capable of 10,000 rev/min and develops up to 1,55Nm of torque through its NC-controlled B-axis swivelling head.

Tool capacity is 120 tools and the 2.5m pallet can be rotated at up to120 rev/min for the combination of turning cycles with multi-axis milling and drilling.

Set beside the DMU 340FD are two further DMG (UK)-supplied five-axis machines, a DMU 160 FD and DMC 125 FD.

The DMU 160 FD has a 1.6 x 1.25 x 1m working envelope and 1.5m diameter 250 rev/min rotary table.

This 44kW spindle machine was primarily installed to produce 200 engine turbine casings a year, replacing a two-machine process involving a vertical turning lathe and machining centre.

The pallet exchange is also important for Manthorpe by reducing lost time to load and unload completed parts while machining continues.

Meanwhile, the smaller DMC 125 FD, which still has a large 1.25 x 1 x 1m working envelope and 1.25m diameter rotary table that is capable of 500 rev/min, is currently being operated by one of Manthorpe's 19 apprentices in his final year.

Manthorpe has also installed a rapid prototyping machine that is fully integrated into its Unigraphics NX-5 CAD to CAM system.

As a run up to the installation of the new cell, DMG (UK) has also loaned Manthorpe one of its latest DMU 70 Evo linear, five-axis machines in order that programmes and tooling can developed.

The DMU 70 Evo linear machines have axis travels of 750 x 600 x 520mm, 35kW 18,000 rev/min spindles delivering 130Nm of torque.

Acceleration in each axis is 10m/sec2 to a rapid traverse rate of 80m/min in X and 50m/min in Y- and Z-axis using linear drive technology.

The NC swivel rotary table is capable of machining angles up to 18 degrees and will rotate at up to 40 rev/min in the B-axis and 50 rev/min in C-axis.

The Gildemeister CTX 520 linear turn-mill centre with counter spindle and 12 driven tools also has linear drives giving 60m/min rapid traverse in X, 15m/min in Y and 45m/min in Z.

Spindle power is 45kW with 750Nm of torque and speeds up to 4,000 rev/min.

The Y-axis is +40 mm.

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