Cycle times cut by versatile lathe

The recent installation of a Harrison Alpha 800S CNC/manual centre lathe has led to a dramatic reduction in the manufacturing cycle times at an aerospace components producer

The recent installation of a Harrison Alpha 800S CNC/manual centre lathe has led to a dramatic reduction in the manufacturing cycle times of a range of high-precision aerospace components produced by Stroud-based Mettis Group company, Nu-Pro Machining Division.

Supplied by Derek Robinson Machine Tools (DRMT) of Leicester, the Alpha 800S is proving a major asset at Nu-Pro after being chosen for its large capacity and celebrated combination of performance and reliability.

Replacing a manual centre lathe, the Alpha 800S also undertakes work previously performed by 2 large vertical borers, operating a 2-shift pattern for the production of a wide range of engine and landing gear parts in metals such as aluminium, titanium, aluminium bronze and S99 aircraft steel.

The Alpha features a swing over bed of 800mm, 2m between centres and a maximum spindle speed of 1500 rpm delivered by a 26 kW motor.

The lathe performs a wide variety of machining operations including general turning operations, threading and contouring, and it was this versatility which contributed to its overall appeal, as Nu-Pro's Engineering Manager, Ken Chandler, explained, 'The fact that the Alpha does everything we could expect from a centre lathe both quickly and accurately made it the perfect choice for the wide range of small-batch applications undertaken at Nu-Pro.

We had looked at a number of possible machines but it was the overall package from Derek Robinson Machine Tools which offered the best combination of machine performance, after-sales support and value for money '.

Nu-Pro's previous satisfaction with products from UK machine tool giant, 600 Lathes, also played an important part in the decision to invest in the Harrison Alpha 800S.

Over the course of the company's 30-year history, operators at Nu-Pro have used a variety of machine tools from fellow 600 Lathes' brand Colchester, and their overwhelming enthusiasm for the Yorkshire-built machines has encouraged a degree of loyalty reflected in this latest purchase, as Ken Chandler explained, 'We were already familiar with the excellent design and build quality of 600 Lathes' products and were more than happy to buy another machine tool from the same stable.

Our customers expect the highest standards of workmanship in everything we produce and so it's vital that we can completely rely on the ability of our machine tools'.

Crucial to the Alpha's success at Nu-Pro is the machine's ease-of-use, which has enabled typical cycle time reductions of up to 40%.

Machine operator, Mike Dixon, explained 'The Alpha 800S is the first CNC lathe I've operated but the machine's Fanuc 21i control and AlphaLink software have made it simple to learn and a pleasure to use, especially for complex machining operations which would have involved painstaking set-ups on a less functional machine'.

As well as reducing cycle times, the Alpha's solid construction and resulting rigidity have enabled Nu-Pro to easily achieve superior surface finishes and tight tolerances within H7 limits required by the company's big-name aerospace customers.

The Alpha has also enabled the trouble-free completion of machining operations that had previously proved more difficult and involved the use of a centre lathe with hydraulic copy attachment.

Ken Chandler explained, 'Long internal contours and profiles on larger components can be performed far more easily thanks to the Alpha's additional capacity and ease of use and we're already beginning to quote for more complex small batch operations, a factor which will lead to new business opportunities as our manufacturing capabilities expand'.

But it's not just the Alpha's considerable ability which has earned the support of those at Nu-Pro; the quality of service and sheer scope of the package offered by DRMT has impressed Ken Chandler and reinforced his certainty that choosing the Alpha 800S made perfect sense.

'The level of service offered by DRMT has been fantastic, from commissioning the machine within one day of its arrival to the provision of carefully phased operator training tailored specifically to Nu-Pro's needs, they've done everything we 've asked of them both quickly and efficiently.

I'd go so far as to say that we wouldn't hesitate to give DRMT our custom again should the need arise, because of the peace of mind provided by their attention to detail'.

Coming with a 24 month warranty and access to 600 Lathes' own dedicated Customer Support Team, it's clear that Nu-Pro has bought more than just a class-leading machine tool.

Summing up the his overall satisfaction with the company's recent investment, Ken Chandler said, 'Quite simply the Harrison package supplied by DRMT offered the right combination of state-of-the-art technology with first-class customer service and technical support.

All things considered, in terms of real value for money it was an offer we couldn't refuse'.

(This was Manufacturingtalk's Top Story on 18 September 2002).

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