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Product category: CNC automatic lathes
News Release from: Geo Kingsbury Machine Tools | Subject: Index CNC turning machines
Edited by the Manufacturingtalk Editorial Team on 13 November 2003

Visitors see new CNC turning
developments at Index

A novel turret guideway system on a CNC single-spindle bar auto is several times stiffer than traditional slideways, has better damping characteristics and is also more compact.

Nearly 50 people from the UK attended an open house exhibition held during September by Index -Werke, Esslingen, Germany, at which new mill-turning machines incorporating major technological advances were launched, including a new model from subsidiary company, Traub Some guests also visited nearby machining centre and universal milling machine builder, Berthold Hermle Maschinenfabrik, as the trip was arranged by Geo Kingsbury, which is UK agent for all three machine tool manufacturers

Managing director, Richard Kingsbury, invited his guests to comment on what they saw, and some of their remarks are recorded below.

First, however, he set the scene by describing briefly the highlights of the show.

Index CS42/65, a single-spindle bar auto with a steeply angled bed, distinguishes itself by a novel turret guideway system having a cast iron plate sliding over ceramic-coated steel strips.

It is several times stiffer than traditional slideways, has better damping characteristics and is also more compact, giving more space in the working area.

X and Z axis drives to the upper turret and lower, double-sided turret, both of which have Y-axis movement, is via kinematic rods behind the bed.

Unusual is the powerful counter spindle which has an X axis as well as the usual Z axis and is electronically coupled with the lower turret, allowing three tools to be in cut simultaneously.

This is achieved by having the upper turret and the left face of the lower turret machining a component in the main spindle while the 'slave' counter spindle follows the latter turret around, enabling a parted-off component to be machined using the right face of the lower turret.

In other words, the X and Z axis movements of the lower turret resulting from the main spindle cutting cycle are continually allowed for in the programmed movements for back-working.

Noteworthy too is polygon generation using a head mounted directly on the counter spindle rather than on a turret, ensuring vibration free machining and hence greater accuracy and longer tool life, especially on alloy steels.

Index MS18C is a multi-spindle auto whose ability to optimise cutting speeds and feeds at each of the six stations, in common with the manufacturer's other multi's, avoids compromised cutting conditions and maximises productivity.

New, however, is faster and significantly extended back-working capability by virtue of a synchronous pick-up spindle that presents the parted-off component to four driven or static tools positioned well away from the area of the drum.

The kinematically-driven spindle, with the option of a second, incorporates a Y axis for machining off-centre features in addition to a C axis.

Conventional CNC multi's with opposed spindles have a restricted number of back-working tools which can move in no more than two axes.

Traub TNX65 is a twin-opposed-spindle, four-turret lathe incorporating new mill-turning capabilities including a Y axis on all 10-station turrets and patented toolholders that obviate axial adjustment.

All turrets can work at either spindle.

Each turret is conical and angled towards the spindles so that the tool is still perpendicular to the component.

This simple expedient allows long boring bars, gun drills or special units such as high frequency spindles to be mounted on the reverse of the turrets.

Normally it is impossible to employ these tools on a lathe as there is insufficient clearance between the back of the turret and the spindle nose.

Another innovation is the ability to replace one of the turrets with a gang tool carrier that can carry a live centre, allowing tailstock support of a shaft-type part in the main spindle so that the remaining three turrets can perform machining tasks on it simultaneously.

Comments from visitors: * Torbjorn Engren, Manufacturing Manager, CP Desoutter UK Sales, Hemel Hempstead, UK: "We use mainly Traub machines here but it was apparent that we only had half the story, as we had not realised how far the parent company, INDEX, had progressed especially in terms of automation.

We have INDEX machines in our French factory and elsewhere in the group and I should not be surprised if we end up with one in the UK as well." * Guy Lord, Managing Director, Automatics Tooling Co (ATC), Redhill, UK: "I felt that Index is really at the forefront of turning technology.

The innovative features built into the CS42 I thought were excellent.

Vertical turning incorporating grinding capability clearly allows great flexibility by cutting out the final operation.

"Insofar as Hermle is concerned, being able to visit the factory allowed an insight into how well built the structures are right across the machining centre range.

I was particularly impressed with the patented Y-axis movement employing three staggered linear guides, giving stable traverse owing to three-point support and a central drive." * Robin Taylor, Managing Director, Turbocam Europe, Fareham, UK: "What was surprising were the leaps in technology that have been made over the past few years in terms of integrating 'state of the art' machining techniques into one neat package.

The MS18C multi-spindle automatic particularly impressed me in this respect." "Hermle too was an eye opener.

Although we are familiar with these machines, as we develop CAM software for them, I had not seen them in build before.

Things that stood out were the technology incorporated into the mineral casting that forms the machine base and the professionalism on the shop floor." * Chris Greenwood, Group Manufacturing Manager, Chas A Blatchford and Sons, Basingstoke, UK: "A number of people on the trip, including myself, believe that to remain competitive in a global market place, UK manufacturers need to invest in the sort of machine tool technology shown at the Index open house and during the Hermle visit, namely fast cycle times, set-up reduction and high accuracies.

As well as seeing the latest machine tool developments, we met many new people and were able to exchange ideas on how to improve many aspects of our businesses." * Dave Norman, Co-Owner and Director, Alpha Tool Productions, Gloucester, UK: "The technology was outstanding in terms of the design and capabilities of machines from both Traub and Index, particularly the MS18C multi.

I have a different view of Traub now, certainly in respect of its sliding-head lathes which I now regard as up with those of the three other main players.

It is clear that for UK manufacturers to compete against low wage economies in Eastern Europe and China, for example, we must put the very best production technology on the shop floor.

Machines like the latest Traub and Index lathes are capable of a high degree of automated, one-hit machining to reduce labour costs and increase the added-value content of parts, allowing manufacturers to enter more lucrative niche markets.

The trip certainly stimulated the thought processes, not least because the guests were able to exchange ideas and experiences with each other.

I got all I wanted from the visit, and more." * John Stephenson, Production Director, Polamco, Bath, UK: "Most notable for me was the MS18C multi-spindle CNC auto, which despite its frightening appearance is actually easy to set and program - perhaps more so than some standard CNC lathes.

The Index visit took me back 20 years when rapid advances in technology meant that every time we went to a machine tool exhibition there were always new innovations to see.

During the 1990s things settled down a bit and changes were more evolutionary than revolutionary.

Now, it seems, the "wow" factor is back again with the latest INDEX multi and other lathes including the genuinely novel CS42." * Fred Moser, Managing Director, Technoset, Rugby, UK: (President of the British Turned Parts Manufacturers Association) "What struck me most about the Index multi-spindle production facility was the high degree of organisation and efficiency.

It is as good as any machine tool factory that I have visited.

The company's latest generation of CNC multi-spindle machines is a most impressive improvement in that technology.

Their power and rigid construction, combined with the comparative ease of CNC setting and operation, offer manufacturers of volume precision turned components huge competitive advantages in high-speed production of complex parts to very close tolerances in difficult and exotic materials.

In the never-ending search for faster, more efficient and cheaper production solutions Index's offering is one which cannot be ignored." * Winston Smith, Operations Manager, Ronaldsway Aircraft, Isle of Man, UK: "Whilst I was interested in the Index mill-turn solutions, the Hermle visit was more relevant to our immediate needs.

I would describe their approach to and capabilities for machine building as being market leading.".

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