A smaller version of an existing ‘mini-mill’ CNC vertical machining centre has a solid cast construction and is designed for medium to large batch production or where many tool changes are used.

The XYZ Mini Mill 450 is a smaller version of the best selling XYZ Mini Mill 560 compact vertical machining centre introduced in 2003.

A response to customer requests for an even smaller, low cost VMC, the 9HP, 60-8000 rev/min Mini Mill 450 features a solid cast construction and weighs in at 1900kg within a 1.6m (W) by 1.8m (D) footprint.

As well as providing a level of rigidity that is second to none, the new machine’s box slides are induction hardened, ground and Turcite coated to ensure smooth running and a high quality surface finish.

Designed for medium to large batch production applications or where numerous tool changes may be required, the Mini Mill 450 has a working envelope of 450mm (X), 320mm (Y) and 380mm (Z), and rapid traverses of 20m/min.

Maximum cutting feed is 10m/min.

Equipped with a 530mm by 320mm table, the Mini Mill 450’s BT40 spindle nose, 10-position tool magazine, auto lubrication and flood coolant complete a ready-to-go package.

An added attraction is a choice of control, while a five-axis option offers significantly reduced set-up times and fixturing requirements.

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Simplifies tool selection. One thread mill can machine all materials up to 58 Rc. This guarantees a safe, highly controllable process, in which a simple modification to the CNC program corrects for material variances. One thread mill can be used for through holes and blind holes.

Produces threads with superior unified form, flank finish and dimensional accuracy. A milled thread satisfies thread acceptability standards according to ANSI B1.3M, for Level 21, 22, and 23.

Eliminates the possibility and consequences of taps breaking. Full bottom threading can be done without modification of the tool.

Pitch diameter can be controlled by CNC machine radius offset. That eliminates the need for special, oversize machine taps that are otherwise required for high-temperature applications that specify a 3BG class tolerance.

Produces optimum concentricity and perpendicularity to the minor diameter. This is a critical thread quality requirement for ring-locked, fluid ports — Rosan Fluid Connection AS1300 — to ensure proper sealing at assembly of fluid fittings.

One thread mill can produce varying thread diameters of the same pitch without affecting tool performance.

Small machines can produce larger threads because they require less spindle torque.

No high-performance lubricants required. That eliminates the need to stop the machine to apply tapping lubricants by hand.

And, thread milling extends tool life over that of machine taps. For example, the average tool life for a machine tap in 6Al4V titanium is 100 to 200 holes. The average tool life for an Emuge thread mill in the same material is 1,800 to 2,000 holes.

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When High Wycombe-based Hempstead and Johnson needed to replace an ageing CNC lathe a few years ago, it chose a Gildemeister CTX 500.

When High Wycombe-based Hempstead and Johnson needed to replace an ageing CNC lathe a few years ago, it chose a Gildemeister CTX 500.

It met the all important physical requirement for one-metre between centres capacity and was available with powered tooling/C-axis capabilities, while the Manual Plus control system provided a high level of local manual programming capability.

“It has proved pound for pound certainly the best machine for the job,” recalls managing director Roy Langley, “and its performance led us to buy two further CTX 400 lathes and two Deckel Maho machining centres - a 63V and a 103V.

We’ve developed a good relationship with DMG, to the extent that we rarely go elsewhere for a machine tool.

The variety of work that we do means that we place a high value on the flexibility and reliability which the DMG machines provide.” Hempstead and Johnson, which is ISO 9002 registered, began as a manufacturer of jigs and fixtures but has evolved into a more general high precision subcontractor.

It produces both discrete components and basic sub-assemblies; one of its key capabilities is the manufacture of components using ceramic for which it has specialist diamond grinding facilities; around 40 per cent of output has some ceramic content.

In addition the company is the UK agent for the Benz range of taper tooling, speeders and angle heads.

It shares its premises with an associated business, Special Drills and Cutters, which produces custom-manufactured drills and reamers.

“We have a lot of expertise and a high level of skills within the company,” says Mr Langley.

“That allows us to take on a very wide variety of work.

Most of our throughput currently relates to components for pneumatic equipment, as well as defence, automotive and aerospace-related work.

Batch quantities of 20-off are typical and most jobs include a significant amount of value added.

Though we supply customers on a just-in-time or kan ban basis we tend to manufacture economic batch quantities based on our own forecast of likely customer requirements.” Hempstead and Johnson regularly deals with cast iron mild and stainless steels, titanium, light alloy, plastics and ceramics.

General turning tolerance is +/-25 microns with six microns roundness and 10 microns flatness and squareness required on turning operations.

Milling capacity is available for up to 500mm cube while turning capacity for bar up to 75mm by 1000mm is available.

Although its turning machines are installed as chucking machines, bar work can be accommodated by supporting the material in the spindle tube and using a bar puller on the turret.

“The defining job when we bought our CTX 500 was a piston rod for a pneumatic cylinder which demanded a meter between centres and facilities for cross drilling and milling.” Mr Langley recalls.

“A lot of the turning work that we do - around 50 per cent - needs second operation capability for generation of end features or flats and cross holes so the availability of powered tooling on the machines keeps our production costs competitive.

Our latest turning machine, the CTX 400 Series 2 also has this facility.

One of the things that we like about the Gildemeister machines is that they have plenty of main spindle power.

As a result they can handle a very wide range of work, combining high metal removal rates with very good accuracy.” A similar line of reasoning led to installation of the two Deckel Maho machining centres, which were bought in successive years to replace existing older CNC machines.

David Lander, works manager, explains.

“On the DMU 103V in particular there is enough space on the table for multiple sets of fixtures so we can achieve a productivity advantage on jobs requiring more than one set-up.

We also like the Heidenhain CNC controls fitted to both machines; the conversational input is well thought out while the remote controller is a very useful feature for setting up; it means that the operator can remain closer to the job throughout.” A recent job completed on the DMU 63V was machining of a prototype air manifold from a solid billet of material as opposed to the more common cast route.

Successful completion of this type of work demonstrates both the capabilities of the machine and the engineering skills of Hempstead and Jonson’s setter/programmer operators.

It also illustrates the savings available to OEMs in respect of flexibility, elimination of pattern making costs, foundry charges and shortened lead times.

Both the DMU 63V and the DMU 103V have 8000 rev/min spindles and 24-tool capacity tool changers.

Hempstead and Johnson has also used them with Benz spindle speeders - which can be interchanged from the tool magazine - to achieve up to 25000 rev/min for machining ceramic.

Depending on the hardness of the ceramic material the machines are used either to complete machining of specific features or to provide accurate spot locations for manual drilling.

Mr Langley concluded.

“We’ve been very happy with the performance and reliability of the equipment that we’ve purchased from DMG.

It has certainly helped to maintain our competitiveness over a period of years by maximising the amount of machining that we can complete in each set-up.”.

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CAM software maker has announced that enhanced capabilities or programming 2- through 4-axis Wire-EDM CNC machines are now available.

Gibbs and Associates, developer of GibbsCAM, computer-aided manufacturing (CAM) software for programming computer numerically controlled (CNC) machine tools, announced today that enhanced capabilities for programming 2- through 4-axis Wire-EDM CNC machines are now available with the latest release of GibbsCAM.

Many of these enhancements are the direct result of feedback from customers and further refines and extends the software to better meet their needs.

Some of the key enhancements are: * User Configurable EDM Technology (EPAK) Settings.

Define standard or custom EPAK settings for rough and skim cuts, store them in a library, and retrieve as needed.

* Part Geometry Associative to Machining Operation.

Automatically creates an associative link between the geometry and the Wire-EDM machining operations.

* Multi-level Part Thickness with Auto-taper Calculations.

For parts with multiple Z-depths and thicknesses, the system can store datum information for each depth, and automatically adjust taper calculations and adjust the wire guides for each depth.

* Automatic Corner Looping.

Adds a switch to the properties of each part enables looping around external corners.

Actual loop extension and radius are a general strategy setting.

Creates external corners (loops) and internal corners (reliefs).

* Subroutine output for patterns of parts.

Automatically repeat a common part (open or closed contour or no-core feature) through a pattern of points (represented by a separate contour).

CNC output can either be created using subroutines, or longhand code (post processor dependant).

* Support for Agie Vision machines.

Full support for cut types, materiel types and wire types along with full support for Agie-style collar cutting.

In addition to these enhancements listed, a number of additional enhancements were made in other aspects of machine control, user interface and post processing.

This latest release of Wire-EDM has been sent to all customers on Software Maintenance and is now available as the shipping version of GibbsCAM Wire-EDM.

About Gibbs and Associates and GibbsCAM - since 1984, Gibbs and Associates has been a leading developer of CAM/CNC programming software that is widely acclaimed for its ease of use and productivity power.

The current GibbsCAM product line supports 2- through 5-axis milling, turning, mill/turning, multi-task simultaneous machining and wire-EDM.

GibbsCAM is available as either an integrated off-line or controller-embedded shop floor programming configuration, which are fully compatible.

High-level process models can be exchanged between the shop floor and manufacturing engineering allowing the capture of shop-proven processes.

GibbsCAM also provides fully integrated manufacturing modeling capabilities that include 2D, 2.5D, 3D wireframe, surface, and solid modeling.

GibbsCAM’s data exchange capabilities are able to access the broadest range of native and industry standard CAD data formats.

GibbsCAM is certified under the Autodesk Inventor Certified Application Program, a Solid Edge Certified Select application, and offered under the SolidWorks Solutions Partner program.

GibbsCAM is either offered or endorsed by a number of leading worldwide control and machine tool manufacturers, including GE Fanuc, Siemens, Fadal, and Mitsubishi.

Gibbs and Associates distributes its products worldwide through a network of international resellers.

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