Brooks Machinery January 11th, 2016 Newsletter
In this Issue:
- Ramping Up Aerostructure Parts Production
- Benefits of Buying Used Machines
- YAMA SEIKI Expanding Technology
- Seven Reasons to Purchase a 5-Axis Machine
Ramping Up Aerostructure Parts Production
A main global supplier to Airbus, Stelia, Alenia Aermacchi, BAE Systems, Boeing, Dassault Aviation, Selex, and others, Abu Dhabi, UAE-based aerostructures component manufacturer Tawazun Precision Industries (TPI) relies on 5‐axis machining centers from German machine builder Handtmann A‐Punkt Automation GmbH to cover numerous applications. Seven Handtmann centers machine aluminum at high speeds, while machines from other manufacturers are dedicated to titanium.
With orders increasing from Airbus, Boeing, and other aerospace customers, Kyle Wagner, operations manager, aerostructures at TPI, says, “A decrease in production volumes is not of any concern at all.”
Along with the international aerospace industry, TPI has been growing constantly for years. The company expects to increase its production by 50% each year for the next three years.
TPI managers try to keep a reasonable balance between aluminum and titanium machining to offer what the OEMs need, which corresponds to a material use ratio of about four to one.
TPI uses seven Handtmann 5‐axis machining centers for highspeed aluminum milling, covering more than 50 unique parts. The PBZ HD 600 profile machining center machines fuselage frames and cockpit frames, center wing boxes, and various beams up to 6,000mm in length. A maximum travel speed of 70m/min in X and 40m/min in Y and Z offers high performance in aluminum machining and appropriate cutting parameters. Two HBZ Compact Cell 200/100 horizontal machining centers – with 2,000mm x 1,000mm tables and stations for main‐time parallel setup – produce a mixture of structural parts, wing sections, and fuselage frames with a 30,000rpm high-power spindle. The centers have travel speeds of 60m/min in X and Z, and 40m/min in Y.
Four HBZ AeroCell 500/200 machines with 5,000mm x 2,000mm pallet sizes are used for high-speed machining of fuselage frames and various parts between cockpit and wings. Any HBZ AeroCell (AC) dedicated part can be machined on any of the four machines. The big pallet size allows several identical parts to be made from one aluminum plate. A 125kW, 30,000rpm spindle ensures high material removal rates and short machining times. The integrated pallet automation increases productivity.
“These machines are brilliant for high-speed milling,” a TPI NC‐programmer says, referring to the HBZ AC as well as the HBZ CompactCell horizontal machining centers. The power the machines get from the horizontal concept combined with high spindle power produce high cutting rates and chip removal for quick cycle times.
Wagner is satisfied with the Handtmann machines’ performance. Cycle times are better than TPI estimated before buying the HBZ AC machines. Rapid feeds, good cutting rates, powerful machines, and efficiency result in satisfying productivity.
Machine operator Vivek is proud of the fact that he was the first person at TPI to touch a Handtmann machine and rates them user-friendly, highlighting the easy setup due to horizontally positioned pallets on the HBZ AC and HBZ CC, good chip removal system, and good visibility of the machining environment. The large HBZ AC also has a video camera for improved visibility while machining.
Capacity utilization on the TPI shop floor is around 100%, but TPI plans to increase the output by 50%. That increase is only possible with powerful machines and improved milling strategies. TPI doesn’t plan to invest in new machinery until current programs have been optimized.
“We want to get the absolute maximum out of the machines. They are so powerful that there is still some potential by modifying and optimizing milling strategies, optimizing programs, and modifying tool selection to reach the best results possible. The machines are not the limitation. There’s still a lot of room for improvement,” according to Wagner. Besides process optimization, TPI will also set a higher priority on machine maintenance and service to keep the machines running smoothly.
As TPI produces 24/7, machine reliability is most important. According to Wagner, spare part deliveries, reaction times, remote diagnostics, problem solving, and training are considered as very industry with a significant role in the international aero structures supply chain because of an excellent reputation for on‐time delivery, on‐time quality, and cost competitiveness, Wagner says.
Article by Robert Schoenberger. Reprinted with permission.
Benefits of Buying Used Machines
When looking for quality products at the best price, buying used machining equipment makes sense. Sometimes buying new isn’t practical or in the budget. When purchasing new equipment, machine shops might have to wait months at a time before they receive the machine. On the other hand, used machines are often available immediately.
A huge benefit to purchasing a used machine, is being able to view and inspect that specific machine. Purchasers are able to see all of the machines capabilities and parts. With a new machine, sometimes only pictures, diagrams, and videos of the machine are available.
While some people look down on the word “used,” it doesn’t always mean hand-me-downs. Often, used machines are sitting brand new, unused, and in their original crates. Don’t let the idea of purchasing used get in the way of savings thousands of dollars.
Books Associates know the benefits that come from purchasing used machinery. That’s why they offer them when they’re available. Visit their website to see the used machines they have in stock.
YAMA SEIKI Expanding Technology
Yama Seiki USA, Inc. held its first annual Open House event recently in celebration of the grand opening of its newly renovated corporate office located in Chino, CA. The event featured live demonstrations of more than 30 high performance turning and machining centers from both Goodway and AWEA. Several of these are new models. AWEA models on display included:
• Horizontal Boring Mills, MB-1512
• 5-Axis Machining Centers, FCV- 620, FV-960
GOODWAY models on display included:
• Swiss Turning Centers, SW-20, SW-32, SW-42
• Multi-Tasking Turning Centers, GTZ-2600Y
• High Speed and High Precision Horizontal Turning Centers (Linear Way), GLS-1500L, GLS-2000 with Siemens 828D control, GLS-2000L, GLS-2000LYS
• High Performance Horizontal Turning Centers (Box Way and 30º Slant Wedge Saddle), GA-2000, GA-2800, GA-3300, GA-3600
• Automation with Robot System, GA- 2000C plus Gantry, GA-2000C plus inmachine Robot
• Maximum Performance Turning Centers, GS-3300Y, GS-3600LY
• Ultra Performance Turning Center GS-4000L2Y
• Vertical Machining Centers, AV-760 and BM-2100
• Vertical Machining Centers - Auto Pallet Changer, AV-860 APC
• Vertical Machining Centers with Robot Automation, AV-650, AV-1060
• Bridge Type Machining Centers, VP- 2012HD
•Bridge Type 5-Face Machining Centers, LP-2516YZF
• Horizontal Machining Centers, EH- 119GR, AH-630
• Heavy-Duty Turning Center, GS- 6800L
• High Speed Vertical Turning Centers, GV-500, GV-780 plus FANUC Robot, GV-1000
• Heavy-duty Vertical Turning Center, GV-1600M
Yama Seiki representatives from the sales, service and parts department provided guided tours for attendees at the three day event. Attendees were able to tour of the facility with the parts area and spindle room available for public viewing. The following partners exhibited at the event: FANUC, Mitsubishi, Siemens, Heidenhain, Samchully Workholding, AllRich, Tecnara, Renishaw, Kenbil, Iscar and Innovative Tool as well as conducted informative seminars.
Seven Reasons to Purchase a 5-Axis Machine
While some machine shops see 5-axis CNC machines as overkill for their day-to-day operations, they can be beneficial. For those on the fence about buying a 5-axis machine, here are seven reasons to take the plunge:
1. New Opportunities
The three linear and two rotary axes move at the same time during the cutting process, reducing cycle time and maximizing productivity. With this efficiency, machine shops can operate successfully in major industries.
2. Not Limited in Uses
The percentage of parts produced in a metal-working shop that require machining on five sides is over 60. This means that even for less complex jobs, the 5-axis machine is efficient.
3. Reduced Labor Cost-Per-Part
Cost is added each time the machine operator touches a part. By moving the piece from machine to machine, extra time is required. A 5-axis machine can help eliminate that unnecessary movement.
4. Less Programming Cost
With these machines, the programmer only needs to load one CAD/CAM file and create a single program. This is a lot easier and less expensive than writing programs for more than one machine tool and multiple operations.
5. Fewer Tools
With all machining being performed in one operation, machine shops can eliminate fixtures, tools, and tool extensions, saving money.
6. Floor Space
With the purchase of a 5-axis machine, some other machines may become unneeded. This will help create extra floor space.
7. Greater Spindle Usage
Instead of sitting idle waiting for another machine tool to complete an operation, it makes the complete part in one operation.
Contact Brooks Associates to find the right 5-axis machine for the machine shop. Check out Hurco’s 5-axis machining centers on Brooks Associates website.
Past Newsletters
December 14, 2015 Machining Newsletter
November 30, 2015 Machining Newsletter
November 10, 2015 Machining Newsletter
October 27, 2015 Machining Newsletter