Tool setting systems ensure batch machining profit

Precision engineering subcontractor uses the latest tool setting technology to minimise set-up times and to get the maximum productivity from its machine tools to make a profit on batch work.

JK Engineering, an precision engineering subcontractor makes use very latest manufacturing technology, including DMG CNC machine tools equipped with a variety of Renishaw touch probes and tool setters.

JK Engineering, located in Hertfordshire, north of London, UK, is owned and managed by John Kenny, an apprenticed CNC machine operator with a background in aerospace and F1 engineering.

When he started the company, Kenny did not have equipment to meet F1 standards.

The company first machined dental and medical components for the Royal National Orthopaedic Hospital.

Kenny said that his company did a lot of simple, 3-axis work that enabled him to slowly replace the older machines with multi-axis equipment.

Once Kenny had this, He went back to his former F1 employer, Red Bull, to and offer his machining services.

According to Kenny, "Much of the work we undertake is very small batch or one-off parts and components; the kind of thing that puts off a lot of companies.

We've been successful for two main reasons: Firstly, we do whatever we must to get the job done on time and to the right quality standards.

Secondly, just as importantly, we use the latest Renishaw tool setting technology to minimise set-up times and to get the maximum productivity from our machines.

This is vital if you want to make a profit on such low-volume work".

* probing - with the company's two, 5-axis Deckel Maho DMU 50 CNC machining centres, JK uses Renishaw OMP40 spindle touch probes and fixed Renishaw NC4 non-contact laser tool setters.

Kenny said that a member of Renishaw's UK engineering team quickly fitted the latter to the DMG machine.

He said: "Jobs are often loaded on the DMUs on small pallets and frequently require multiple tool changes, sometimes as many as 30.

We use the Renishaw OMP40s to quickly establish the part datum, then we use the NC4 to automatically set the tools and to monitor for tool breakage during the program".

Very obviously, the consequences of a machine left running unmanned with a broken tool would be nothing short of disastrous.

In the Renishaw report to manufactuingtalk.com, Kenny said that material is ridiculously expensive, and getting more so all the time.

"We're using a lot of titanium and aerospace grade alloys so we don't want scrap and, given the very small quantities and tight deadlines, we can't afford to be running a job twice".

In the last seven years since JK Engineering started, Kenny has replaced almost every piece of machinery and softwaret.

As well as the two state-of-the-art DMG DMU machining centres, he operates a new Haas VF-2 Super speed vertical machining centre with a 4th axis and two CNC Colchester turning centres with driven tooling.

To generate the CNC programs the company uses a 3D Open Mind Hyper Mill CAM system.

JK has installed a clean room inspection area.

Kenny added: "Having the equipment is only part of the story, using it effectively and efficiently is vital".

The Renishaw equipment allows the company to minimise unproductive set-up time, avoid costly errors and deliver a good quality product on time, every time.

"In the future, we plan to buy machines with even more tools, so set up and monitoring becomes increasingly important.

It's not rocket science," Kenny said.

"On the contrary, the Renishaw equipment is very easy to use.

I know other companies that have invested in a similar combination of machine and probe technology to do similar work and they're successful, too.

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