CNC bed mill machines cell door tooling plates

CNC bed-type milling machine has than paid for itself in the machining of the 32 tonnes of steel for tooling plates used in the robotic fabrication of prison cell doors.

Fern Engineering Systems is using an XYZ SMX 5000 manual/CNC bed mill to machine various sizes of steel tooling plate for a self-contained robotic welding cell.

The bed mill, with solid Meehanite ribbed cast iron construction and induction hardened and ground slides and Turcite-B coated ways, has been in continuous use since its installation.

Owner of Fern, Andrew Beckley said the bed mill had more than paid for itself in the machining of the 32 tonnes of steel needed to produce tooling plates for the robotic welding cell.

The welding cell is for Cell Security, which will produce different designs of cell doors destined for prisons, police stations and other security applications worldwide.

At Welding Security, the tooling plates can be changed in 10 min or less, allowing various designs of cell door to be fabricated quickly and accurately in a wide range of sizes.

Located at Whitebirk, Blackburn, Fern was set up by Andrew Beckley and Paul Jackson in January 2004.

Fern has always had a company policy to control the entire manufacturing process, which is why Fern took delivery in 2007 of the XYZ SMX 5000 manual/CNC bed mill.

The SMX 5000 has a 5.75kW (7.5HP)/5000 rev/min main spindle serving a 1930mm by 356mm table having a load capacity of 850kg.

X- and Y-axis travels are 1524mm by 596mm.

These specifications made the SMX 5000 an ideal choice for the machining of the various sizes of steel tooling plate used in Cell Security's robotic welding cell.

* Robotic welding cells - on average Fern Engineering Systems builds and ships a bespoke automated welding cell every 8.6 weeks, each one designed as a skid-mounted unit for ease of transportation and installation.

It took less than 12 weeks - from the initial enquiry from Cell Security to delivery on site - and just over 4h for the welding cell to be fully operational.

Before welding cell installation it took up to 10h for Cell Security to construct and manually weld each security door.

The robotic welding cell does the job in as little as 40 min.

Fern employs eight people and Beckley said it is important to maintain the flexibility and fast response of a small business.

This, he adds, requires every member of the team to be multi-skilled.

So, although a control engineer by training, he is equally at home developing and refining the company's proprietary Supervisory Control and Data Acquisition (SCADA) software or machining components for the latest project.

He said: "Engineering companies that we know do good work have XYZ machines and we took note of their recommendations when it came to our choice of machine tool".

XYZ told manufacturingtalk that it was a demonstration at XYZ Machine Tools' regional showroom in Blackburn that provided convincing evidence to Fern of the manual/CNC bed mill's metal removal capability and the ease of use of its ProtoTRAK SMX control.

This latest-generation CNC is deesigned for 'one-off' and low volume production.

The CNC uses plain English prompts and requires no learning of codes, allowing an operator with little or no CNC experience to operate the SMX 5000 within a day, said XYZ.

"It is this ease of use that really appeals," said Beckley, "As it is in line with our own business practice.

We were, for example, awarded a contract by a major automotive parts manufacturer for a system to control 71 automated welding cells after we were able to demonstrate conclusively the flexibility and cost savings achievable with our custom-written Production Management Tools software compared with more expensive off-the-shelf SCADA packages.".

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