CNC machine tool choice wins success

A UK company identified a niche market for a well-specified machine shop that was flexible enough to meet turnaround times of say, two days, for low volume precision parts.

North East Engineering, a UK start-up company that has already developed a strong order book for the oil/gas and power generation industries, has centred its machining operations around machine tools supplied by Ward CNC of Sheffield.

The machine tools include the following.

* Takisawa Taiwan EX-310 3-axis slant bed lathe.

* Hartford Omnis 1270AP heavy duty, open-fronted vertical machining centre.

Established in Newcastle in May 2007 as a fast response precision machine shop, founders Lee Miller and Mark Ranft can draw on more than 25 years' experience gained in the sub-contract, defence and sub-sea oil and gas fields of manufacture.

Miller said: "We identified a niche market for a well-specified machine shop that was flexible enough to meet turnaround times of say, two days, for low volume precision parts.

We find that many of our larger competitors cannot cope with lead times this short".

In order to get the company up and running, it needed to invest in high specification turning and prismatic machining capability.

Initial investigations led the duo to conclude that Japanese models were beyond their budget.

Having researched a number of other suppliers, the shortlist was narrowed to two potential suppliers, including Ward CNC.

Miller explained: "There were several factors that helped us decide to purchase the Takisawa Taiwan and Hartford machines.

First, their build standard is excellent.

In fact, in comparison with Japanese machines, I have to say there is very little difference in construction quality - just a huge difference in price".

He added: "Both machines are also extremely well equipped, as standard.

They pretty much come with everything a machinist needs to get going.

Some competitor machines may start off with a cheaper basic price, but by the time you add everything that's needed, the final price is often prohibitive".

The 75/77 mm bar capacity three-axis Takisawa Taiwan EX-310 universal slant bed lathe with C-axis and 12 driven tools features a 495mm swing over the bed, 845mm between centres, and a maximum turning diameter and length of 350mm and 710mm, respectively.

With spindle speeds of 35-3,500 rev/min and rapid feeds of 20/24m/min, the machine was supplied also with the following.

* 12in chuck.

* Two live 'face' tooling attachments.

* Two live 'radial' tooling attachments.

* Complete Sandvik tooling package.

* A tool-setting arm.

* Fanuc 21iT control with Manual Guide programming system.

"I had not used live tooling before but it has proved extremely useful for our type of work," said Miller.

"When the Hartford machining centre is fully loaded we can put prismatic jobs on to the EX-310 and use the live tooling almost as effectively.

There are many jobs that we don't think of as traditional 'turning jobs', but with the live tooling we can pretty much do anything.".

The Hartford Omnis 1270AP arrived at North East Engineering equally well equipped.

It came complete with the following.

* 24-station automatic tool changer.

* 20-bar through-spindle coolant.

* An extensive range of Kennametal toolholders.

* Fourth-axis indexer fully integrated to the Fanuc 0i MC control with Hartrol Ai 100 programming system.

Able to accommodate loads of 950kg on its 1370mm by 600mm table, the machine has X-, Y- and Z-axis travels of 1270mm by 635mm by 635mm and spindle speeds of 60-8,000 rev/min (pulley) and 40-6,000 rev/min (geared) from the 11/15kW spindle motor.

Its fourth axis interface is standard and, continued Miller: "Although we specified the fourth axis to avoid second operations on the work we had coming up, word is already spreading that we have this facility and it is attracting new work that we didn't expect".

In particular, the Hartrol-Fanuc control is quoted as playing a key role in the machine's high productivity.

The control system features a series of advanced functionality programming routines available as standard; a series of easy-to-use cycles designed to simplify and speed up programming times and therefore reduce downtime along with other useful setting and maintenance functions for ease of operator use.

Indeed, the functions can make users up to 10 times more effective compared to other controls.

The routines embrace, for example, workpiece datum setting using edge setter, manual tool setting using calibrated setting block, tool magazine tracking (for arm-type ATC), tool logging and spindle load monitor, as well as full M Code listings and a comprehensive set of special canned cycles.

Miller added that both machines are capable of comfortably holding tolerances in the realm of 0.01mm all day long, producing a range of oil/gas and power generation components from materials such as nickel alloys, Inconel, aluminium-bronze alloys and a number of alloy steels.

"I can't fault the machines' accuracy, quality of build or price," he said.

"I also cannot speak highly enough of the Ward CNC commissioning engineer - the entire process was totally painless.

As a new business we aim to provide first class, value-for-money products.

Our number one aim is customer satisfaction and I am pleased to say that Ward CNC obviously upholds similar values.".

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