Product category:
CNC turning centres, mill/turning, multi-tasking centres, horizontal and VTLs.
News Release from: Mori Seiki UK | Subject: Mori Seiki ZL-203 CNC turning centre
Edited by the Manufacturingtalk Editorial
Team on 19 June 2003
Mill-turning centre eliminates multiple
set-ups
When a major aero engine customer wanted shorter manufacturing lead times for pipework assemblies, B and D Patterns acquired a multi-function mill-turning centre to reduce set-ups.
When a major aero engine customer wanted shorter manufacturing lead times for pipework assemblies, B and D Patterns turned to multi-function machining A twin-spindle, twin-turret turning centre proved to be 40% quicker, and it reduced lead times, when compared with multiple set-ups in 2-axis lathes and machining centres
This article was originally published on Manufacturingtalk on 5 Jun 2001 at 8.00am (UK)
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In the manufacture of engine pipework assemblies, B and D Patterns has to produce a variety of weld fittings such as threaded adapters and flanged adapters.
These were turned in two set-ups, in 2-axis CNC lathes from very tough S-130 aerospace grade stainless steel bar - up to 75-80mm diameter.
A 3-axis CNC miller or machining centre then milled various features and drilled holes in the interpolation-milled flanges.
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Now, the threaded adapters are completely machined from bar in one Pollard Mori Seiki ZL-203, twin-opposed spindle, twin-turret CNC turning centre.
B and D Patterns has a second machine on order to be installed shortly for machining the flanged adapters.
In a typical operation, a flanged adapter - typically a machined 18mm diameter barrel, about 50mm long, with a centrally located polygonally-faced and drilled flange of some 50mm OD - is first turned down to within 0.03mm or so of a 1/2in UNS thread OD.
It is then threaded, grooved, drilled, bored and chamfered in the main 200mm spindle.
The 150mm sub-spindle then locates onto the threaded OD, while the first turret parts-off the adapter from the stock bar.
The sub-spindle then presents the adapter to the second turret for profile machining the back end of the barrel up to the flange.
The profile includes a weld preparation and weld filler 'lip1 at the end of the barrel for autogenous-TIG welding to pipework.
At the same time, the bar is fed forward to a stop in the first turret, and front end machining commences.
Before, the front and back end turning of the adapters was performed in two set-ups in 2-axis CNC lathes.
Milling and drilling of the flange was performed in a third set-up on a machining centre or CNC miller.
Faster throughput and less waiting time - "By hitting machined details in fewer operations, we get a faster throughput and, importantly, less waiting time," said joint managing director of B and D Patterns, Ian Burton.
"Multi-function turning centres also give us more manufacturing flexibility." Operational flexibility is very important to us especially on the adapter range," said Burton.
"We change sizes very quickly.
In the long term, we want to eliminate set-ups, batch-to-batch, and get batch sizes down to what we want to make, rather than aim at minimum batch sizes.
The ZL-203 allows us to do just that." When asked what was driving the investment in higher specification machine tools, Burton replied that aero engine manufacturers, such as Rolls-Royce, are aiming at much shorter engine build lead times, typically 40 days from receipt of materials to final engine testing.
"It is a very challenging project," said Burton.
"The engine manufacturers are being pushed by their customers and, in turn, they push us! Therefore we try our hardest to support them.
Consequently, companies like us are getting involved at the design stage in new engine details.
It provides more opportunity for all involved to develop costs out of the final design." Continuing, Burton added: " Having acquired high specification machines, it brings a bonus of attracting new customers to us.
We give them more confidence in our abilities and is also helping us to diversify into other high-tech markets, such as Formula One engine components and marine work." B and D Patterns had the Pollard Mori Seiki ZL-203 installed in January 2003.
Essentially, the machine has replaced one 2-axis lathe and one 3-axis CNC miller, as well as adding capacity.
The second ZL-203, due to be installed at the end of July, will replace a single turret, C-axis, CNC lathe and add even more capacity as well as machining the flanged adapters in one set-up.
The flanged adapters, also machined from S-130 bar, are similar to the threaded adapters, except they have a much larger milled adapter profile.
Burton said that machine rigidity is a very important factor as the S-130 material is free-cutting, but does not chipbreak easily and has a tendency to 'nest1 around the workpiece.
Both adapter styles are machined to within a general OD tolerance of 0.05mm and on lengths to within 0.06mm.
B and D Patterns1 machine operators are also responsible for carrying out 100% inspection of the adapters - verifying features and details - and are supported by inspection audits.
The S-130 adapters currently come in nine different varieties and are generally machined in batches of 100 - 300 parts.
Consequently, most of the work on the ZL-203 is repetitive, so CNC program selection and any editing required, is done by the operator.
B and D Patterns operates a central programming facility serving some 28 CNC machine tools.
Pollard Mori Seiki has supplied 13 of these in recent years.
The reason for buying more Pollard Mori Seiki machines, according to Burton, is that their reliability outweighs the 'unknowns1 of cheaper machines.
"There are cheaper multi-function turning centre versions out there, " said Burton.
"But they do not have the reliability - or the rigidity - and both factors are very important to us." Technical Partnership pays dividends - that is one of the many reasons that encouraged B and D Patterns to take up a Technical Partnership with Pollard Mori Seiki in early 2002.
"The partnership gives us advice on cutting tool selection, methods as well as advice, training and support - important when taking on higher spec, multi function machines," explained Burton.
"We took up the partnership shortly after acquiring our first multi-function machine, the Pollard Mori Seiki MT 2000 heavy turning centre.
That machine made us look at machine tools in a totally different way.
Before, we had concentrated on 2-axis CNC lathes and CNC millers.
Now, higher specification, multi-function machines is the way for us" "When the ZL-203 arrived, there was consequently not much of a learning curve to overcome," said Burton.
"A few operators were initially nervous, but confidence soon built up." "The Technical Partnership also changed our tooling procurement policy," said Burton.
We used to buy from everyone.
Now, we concentrate on one supplier, Matrix Tooling Services in Nottingham, who also keeps eyes on tooling developments." "Yes, we feel that the technical partnership has been good for both parties," said Burton.
"They are products we feel comfortable with and have given us confidence of no longer having to look for other machine tool suppliers." Commenting on the Technical partnership, Pollard Mori Seiki1s Area Sales manager, Paul Barradell said: "We have established a good working relationship - it certainly takes the 'pain1 out of customer liaison.
In return, we can bring potential customers to B and D Patterns1 factory and show the Mori Seiki machines in action." As mentioned before, B and D Patterns will be installing its second Pollard Mori Seiki ZL-203 at the end of July.
In light of a steady recovery now taking place in its business, the company plans to replace seven machine tools over the next two years.
The oldest machine at B and D Patterns is 11 years, and average machine age is just five years.
Pollard Mori Seiki ZL-203 - the ZL Series are 'heavy duty1, four-axis CNC lathes fitted with twin opposing spindles - an 8in, (200mm) 11/7.5kW main spindle and a 6in (150mm) opposed sub-spindle - and two turret slides, the top one carrying a 12-tool turret and the bottom carrying an 8-tool turret.
Maximum turning diameter and length are 390mm and 424mm respectively.
Spindle speed range is 40-4,000 rev/min on the main spindle and 60-6,000rev/min on the sub-spindle.
The two turrets can machine at each spindle independently, or work simultaneously on either spindle.
Equipped with Mori Seiki1s MSG 501 CNC and MAPPS operational management system, very complex workpieces can be quickly programmed.
Workpiece examples include small crankshafts, pump and valve parts and aerospace and engine components machined from tough ferrous and non-ferrous alloys.
The MSG 501 CNC includes command increments down to 0.001mm, a load monitoring function, 240 tool offsets, background editing and RS-232-C and PCMCIA (I and II) ports.
The MAPPS operational management system includes programs for soft jaw turning, Y-axis machining, back-end turning, program editing, tool list, time study and operation simulation.
The CNC and MAPPS are contained in one panel.
There is also a wide range of options including, for example, bar feeder and work probing systems.
B and D Patterns - as a preferred supplier of pipework assemblies to Rolls Royce1s aero engine group, B and D Patterns places great emphasis on the rigidity, accuracy and reliability of its machine tools.
B and D Patterns is one of two leading European pipework suppliers to Rolls Royce aero engine divisions has built a new GBP 2.5m, 40,000ft2 facility in Hinckley, Leicestershire.
Pipework assemblies, for engine cooling, fuel rails, fuel systems, lubrication, and so on - often referred to as 'pigtails' - are produced from CNC manipulated tube stock up to 50mm diameter.
Forgings and castings, in a variety of metals, including austenitic stainless steels, Nimonics, Inconels and Titanium alloys, are completely machined in a variety of makes of machining centres and turning centres.
Machining includes machining weld preparations and oil-seal grooves, and all dimensions are generally to within 0.01-0.02mm.
B and D Patterns operates extensive welding facilities, including PC-controlled orbital TIG (Tungsten Inert Gas) welders.
All welds have to be examined using dye penetrant and X-Ray inspection procedures.
Originally set up in 1961 as foundry pattern makers, the company, led by Mark and Ian Burton, entered into production engineering, producing pipework fixtures for Rolls Royce Engines Divisions in the 1970s.
The aero engine work expanded into pipework assembly, including machining fittings, pipe manipulation and fabrication.
At present, Rolls Royce has seven pipework suppliers in Europe, but is rationalising them to two: B and D Patterns in the UK and one Spanish supplier.
Therefore, B and D had to increase production volumes and take on additional parts.
The GBP 2.5m investment in the Hinckley facility has brought together operations from four separate B and D Patterns sites and extended capacity.
Altogether, the company employs 125 in Hinckley and operates 28 CNC machine tools including pipe benders.
The expansion will increase the direct labour force by some 10-15%. Request a free brochure from Mori Seiki UK ...
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