Product category:
Horizontal machining centres (HMC)
News Release from: Heller Machine Tools | Subject: MC 25 horizontal machining centre
Edited by the Manufacturingtalk Editorial
Team on 15 December 2003
HMCs, not VMCs, machine superbike's
engine parts
Departing from its established practices, a UK motorcycle manufacturer has installed eight HMCs to machine engine parts for a 2.3litre high performance model that will hit the roads in 2004.
Working in partnership with Triumph Motorcycles Heller Machine Tools has built and installed eight MC25 horizontal machining centres to machine the engine for the new Rocket III motorcycle, the first production motorcycle to break the 2 litres barrier Four of the MC25s form a cell to machine the cylinder head, the other four a cell to machine the upper and lower crank case, which after assembly is finish machined on the MC 25 including the crank bore, gear shaft bores and cylinder bores
This article was originally published on Manufacturingtalk on 27 Feb 2002 at 8.00am (UK)
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The Rocket III has a unique fuel-injected, twelve-valve, longitudinally-mounted, in-line three-cylinder engine with a cubic capacity of 2,294cc - 140 in3 - and uses the same size pistons as a ten-cylinder American muscle car.
Peak torque is 147ft.lbf at 2,500rpm, pulling 1.2G in the process.
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It delivers over 90% of peak torque between 1,800 - 6,000rpm.
Triumph itself say "Awesome is an over-used word - except when applied to the Rocket III.
Then it is only barely adequate".
When Triumph first began to this important new engine development, Triumph's Production Supervisor Russ Daleman, knew exactly what the new production facility needed to achieve.
He sought a machine tool supplier which could help him translate the ideal into a workable reality, creating not only an efficient production system but a flexible facility which could be used with ease for further motorcycle new engine projects.
In the long term, this would enable him to reduce the launch time to market of any new motor cycles.
One of the main reasons for choosing Heller was their engineers automotive experience and willingness to work closely with him and his team to create the production facility he required.
Supporting their decision to work with Heller was the Heller UK plant responsible for building the very machines that they required and their strength in depth to handle the project at all of its phases.
Russ involved Heller engineers from the outset of the project, whilst the engine design was still fluid, enabling the manufacturing cells to be fine-tuned to suit the engine components but also allowing the design to be modified if necessary to permit the most efficient production system.
Working together, Triumph and Heller engineers were able to establish the best manufacturing processes in conjunction with the engine designers requirements.
The eight MC25 machines were supplied with all necessary options to meet the Triumph technical specification.
Heller also designed and manufactured the hydraulic fixtures and worked with the tooling supplier, Mapal, to develop the most suitable tooling package.
In addition, Heller supplied and installed a roller tracking system which operates between the machines and which was designed to ensure that swarf and coolant remains within the machine system.
Specifically for the crank case cell, Heller designed an overhead gantry mounted manipulator for loading components.
Two manipulators were installed, one for use with the upper crank case and the other for the assembled crank case.
In order to change over the production to different product types Heller has supplied a hydraulically activated truck which will accurately dock in front of the machines and quickly remove both machine pallet and fixtures.
This ensures quick and efficient changeovers to be made.
Manufacture of the machines and fixtures for the cylinder head started at Heller in November 2002 and were completed ready for prove out in early February 2003.
After completion of a successful prove out by the Heller Application Engineers the machines were transferred to Triumph for installation during April.
Similarly, the crank case machines were built during January and February 2003 with the fixtures completed in April.
Following prove out at Heller these machines were installed in July at Triumph.
During the try out phase at Heller pre-production motor cycle engine parts were supplied to Triumph for pre-production engine build.
Full engine production will commence early in 2004.
Heller MC25 horizontal machining centre - the Heller MC 25 horizontal machining centre is taken from the successful market proven range of MC machines built at Heller Redditch.
They are Heller's fourth generation of horizontal machines which, since their launch in 1999, have close to 3000 installations.
The MC 25 is supplied with either Siemens 840D control or Fanuc 180i and benefits from state of the art axis control and low wear ball screw drives.
X, Y and Z axes are designed with linear ways with pre-loaded roller ball elements.
The machine is equipped with a swivel pallet changer and a work piece setting station with 4 x 90deg indexing.
The rapid tool change of 1.8 seconds equating to a chip to chip time of 2.8 seconds provides class beating tool changing.
Spindles with speed ranges of either 8000 rpm, 16000 rpm or 24000 rpm have tool locations ISO 40 or HSK 63A are cooled motor spindle type.
Rapid traverse rates for the MC range of machines are up to 90 metres per minute with an acceleration rate of 1G assisting greatly with Heller's tradition of providing the best possible piece part cost.
The MC 25 carries two pallets 500mm x 630mm and has axis travel of 800mm in X,Y and Z. Request a free brochure from Heller Machine Tools ...
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