The Magazine for Production Engineers JUNE 2011journal-download.co.uk/digitalmagazines//my/my02jun2011fullmy.pdf · The Magazine for Production Engineers JUNE 2011 SPONSORED BY

The Magazine for Production Engineers JUNE 2011

SPONSORED BY

Fi v e- A x i s SupplementMACHINING – TOOLING – WORKHOLDING

CADCAM– INSPECTION

www.machinery.co.uk

5 coveraxis.qxp:Layout 1 25/5/11 14:04 Page 1

Reduce your gauging costs

Nothing compares to Equator™

The unique new Renishaw Equator™ is a versatile alternative

to custom gauging, offering inspection of an unprecedented

variety of manufactured parts. Developed and proven on the

shop-fl oor with industry-leading gauging users in multiple

industries and applications, Equator 300 is the fi rst of a range

of gauging systems from Renishaw.

Highly repeatable master and measure technique

Thermal stability through simple re-mastering

Nothing compares like Equator™

Versatility – operators change parts in seconds; engineers

adjust programs for any part design changes

Speed and form measurement with the industry standard

SP25 scanning probe

Automation and feedback – interface with robots and

machine tool controls

Plug and play – rapid installation, single phase, no air supply

Call +44 (0)1453 524111 now to request details

or download at www.renishaw.com/gauging

Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR United Kingdom

T +44 (0)1453 524111 F +44 (0)1453 542901 E [email protected]

www.renishaw.com

P002_MCSP_JUN11 23/5/11 07:08 Page 1

3

INTRODUCTION/CONTENTS

FIVE-AXIS SUPPLEMENT

www.machinery.co.uk • June 2011

Five-axis technology development and

uptake continue apace.

In our first feature, which concentrates on

machine tool technology in action, the

University of Warwick is pushing boundaries

in 5-axis machining, marrying it with CO2

cooling to allow the cutting of materials such

as titanium.

Elewhere, in the CADCAM area,

GibbsCAM, for example, has some new

developments to talk about, while in the

tooling and workholding field, reduced

setting times keep 5-axis spindles running

longer, we report.

Finally, we highlight how 5-axis machined

parts can be measured effectively.■■

The power of five

CGTech 01273 773538

CMS 0115 977 0055

DMG 01582 570661

Dormer Tools 0870 8504466

Delcam 0121 766 5544

Faro 02476 217690

GF AgieCharmilles 02476 538666

Haas Automation 01603 760539

Hardinge 01162 869900

Heller Machine Tools 0121 275 3300

Hexagon Metrology 0870 446 2667

Hilcliff Tools 01483 266780

Hurco 01494 442222

Leader Chuck Systems 0121 771 4843

Mills CNC 01926 736736

Mori Seiki 0844 800 7647

NCG CAM 01223 863911

Nikon Metrology 01332 811349

Open Mind Technologies 01869 290003

Phase Vision 01509 839000

REM Systems 01452 314100

Renishaw 01453 524524

Sandvik Coromant www.sandvik.coromant.com

Schunk-Intec 01908 611127

Sescoi 0844 561 7014

SolidWorks 01223 346900

System 3R 02476 538653

Tech CADCAM 01284 754781

Vero 01242 542040

WNT 0800 073 2073

Yamazaki Mazak 01905 755755

Editor: Andrew Allcock – Contributing Editor: Steed Webzell – Art Editor: Neil Young – Sales Director: Joe Opitz – Sales Manager: Laura Cunningham

Account Manager: Stuart Tarrant – Publishing Assistant: Lyn Evola – Circulation Manager: Chris Jones – Production: Heather Upton – Publisher: Peter Knutton

A Machinery supplement: © 2011 Findlay Media, Hawley Mill, Hawley Road, Kent DA2 7TJ – 01322 221144. Email: [email protected] ISSN: 1753-0482

Origination: CTT (Camden Town Typesetters), Walthamstow, London E17 6BU – Printed by Wyndeham Heron, Heybridge, Maldon, Essex CM9 4NW

Supplier index

Contents

04 – Machining

11 – CADCAM

17 – Tooling/workholding

21 – Inspection

You can find further contact details and related editorial for many of the included

companies, together with more product news, at: www.machinery.co.uk

SPONSORED BY

5axis_Intro_cont.qxp:Machinery 25/5/11 15:27 Page 3

Foundry Road, Stamford, Lincs. PE9 2PP

Tel: 01780 765965Fax: 01780 765877

e-mail: offi [email protected]

The E Series Concept

Combines conventional, manual

data input and CNC versatility

within one machine and control

system

E30/E40/E50/E60/E70

Innovative Performance

E90/110/120/150/175

Oil and gas industries

• Robust design for precision

and stablility

• Multiple tooling turret options

• Large spindle bores upto

580 mm diameter

• Automated cycles fast and

simple communication

between man and machine

Apprentice, vocational training

• Machining of

simple/complex components

Injecting 5-axis machining into the mindset

of future generations of production

engineers begins at education level, and

more and more learning establishments are

investing in this innovative technology to

attract students keen to adorn themselves

with a broad understanding of complex

machining.

For instance, postgraduates studying for

doctoral research degrees in manufacturing

at the University of Warwick will soon have

access to the facility’s fourth 5-axis model,

following the decision by one of the

university’s academic departments, WMG,

to install a DMU65 monoBLOCK from

long-standing technical partner DMG

(01582 570661).

The new machine will be the first in the

UK from this German manufacturer to be

fitted with CO2 cooling. The continuous

stream of refrigerated gas can be used in

place of the more usual fluid coolant to flood

the machining area at the point where the

cutting tool meets the workpiece.

“The advantages of the technology when

machining titanium and exotic alloys include

less contamination of the workpiece, better

surface finish, longer tool life and the ability

to use elevated cutting feed rates for higher

productivity,” says Roger Bull, technical and

facilities officer at WMG. “It is said that

cryogenic CO2 cooling also allows PCD tools

to machine ferrous metals, which is not

normally possible, due to the high affinity of

carbon with iron.”

MICRO-ANALYSIS STUDIES

Research carried out at Warwick, which will

include micro-analysis to study comparative

surface grain structures of the tool, chip and

component, with and without CO2 cooling,

will be of mutual benefit to both WMG and

machine tool supplier DMG.

“Our priority has been on 5-axis machining

capability for some time, in order to make

the components our students were

designing on ever more powerful CAD

systems,” says Mr Bull.

Graduated students will take these skills

out into industry, where increasing numbers

of manufacturers are installing 5-axis

machining technology to embrace a growing

culture of low volume, high complexity

component orders. A good example can be

seen at Rotherham-based subcontractor,

Cutting & Wear Resistant Developments,

which has reduced cycle times by as much

as 50% on selected parts with its recently

installed Doosan 5-axis machining centre

from Mills CNC (01926 736736).

The machine, a VC630 5AX, is being used

to machine complex parts for the oil and gas

sector, typically down-hole tool technology in

batches up to 15-off.

“In the past, we were relying on our older

3-axis machines to produce these parts, but

we could see that ‘one-hit’ machining was

4 June 2011 • www.machinery.co.uk

Access all areasThe benefit of motion in five axes continues to appeal to an ever wider

plethora of manufacturers, all seeking competitive gain when machining

complex parts. Steed Webzell reports

BAW opted for Hurco technology to support full

5-axis machining capability

5axis_machining application.qxp:Machinery 25/5/11 15:40 Page 4

the way to go. Reducing both cycle times

and the number of job set-ups required to

manufacture the components were obvious

advantages,” says workshop manager John

Kennedy.

“Mills recommended their Doosan VC630

5AX, 5-axis model. We liked the machine’s

ability to perform high accuracy 5-face

machining (3+2 positional 5-axis machining),

and the potential for us to move into full 5-

axis simultaneous machining in the future.”

Another progressive subcontractor to

invest in the latest 5-axis technology is

Swansea-based BAW Precision Engineering,

which emerged from the global downturn

under new ownership in July 2010. The

management team has installed a culture

of employee training and lean manufacturing,

supported by investment – the company’s

latest asset is a new VMX30U 5-axis

machining centre from High Wycombe-based

Hurco (01494 442222).

“Despite already having 3+2 axis set-ups

on our existing machines, we acknowledged

that we needed full simultaneous 5-axis

capability to drive the company forward,”

explains operations manager Andrew

Hoseasons. “We have identified a need in

the marketplace and the new Hurco will be

our first step to filling this gap.”

IMMEDIATE IMPACT

Richard Gunn, group engineering

development manager of RG Tooling, BAW’s

development arm, is keen to highlight the

immediate impact of the Hurco VMX30U,

with its integrated trunnion table.

“At present, we are machining toolholders

for sister company Eurogrind, a manufacturer

of standard and bespoke milling and turning

toolholders,” he says. “Previously, our square

shank toolholders underwent three individual

set-ups that took 10 minutes each. Added to

the set-up times were three machining

cycles of 15 minutes each, resulting in a

complete part time of 75 minutes per

toolholder. Now, the new VMX30U only

requires one 10 minute set-up and one 15

minute machining cycle.”

To put the saving in perspective, BAW

machines the toolholders in batches from 10

to 30, with an annual production exceeding

500 units.

One of the niche markets BAW is

targeting is the oil and gas/hydraulic valve

sector. The company set this strategy in

motion when specifying the VMX30U: the

trunnion table, with a 420 mm face plate,

accommodates a diverse range of chucks

and is suited to producing complex valve

components.

Also with an interest in this industry is

Gateshead-based subcontractor NTG

Precision Engineers. Its decision to switch

focus around five years ago to supplying

precision-engineered components to sectors

such as power generation, and oil and gas,

has proven very successful. The move has

certainly allowed the company to continue its

planned programme of investment, the latest

addition to which is a travelling column VTC

800-20 SR, a large capacity 5-axis

simultaneous machining centre supplied by

Yamazaki Mazak (01905 755755). The new

machine supports its existing Mazak Integrex

300-IV ST, a twin-spindle multi-tasking

machine, capable of simultaneous 5-axis

turning and milling.

BIG STEP FORWARD

“We were initially looking at a larger vertical

3-axis machine, but that wouldn’t have given

us the step-change in technology we were

seeking,” says works director Charlie Sampy.

“We eventually decided on the Mazak VTC,

which was another big step for us, in terms

of initial investment, but again we were

5

MACHINING



DMG 5-axis machining + CO2 at WMG


Drilling Down Production Costs with High Productivity Hole Making

12xD and up Range of 6-32.9 mm8xD5xD3xD1.5xD

ITA recommends the optimal tool based on application parameters and your machine power.3 tool options, 25 alternatives, cutting data, power consumption, cutting time, metal removal rates, engineering support and more

For more information, view this interactive ad at www.iscar.com

Delivering

Profitability

I S CAR Gua r an t ee s Re su l t s

www.iscaruk.co.uk

P006_MCSP_JUN11 25/5/11 15:13 Page 1

HORIZONTAL /

VERTICAL LATHES

FOR ULTRA

PRECISION

TECHNOLOGY

Foundry Road, Stamford, Lincolnshire PE9 2PP

Tel No. 01780765965; Fax No. 01780765877

e-mail: [email protected]

www.kyalmachinetools.co.uk

careful and initially only targeted work from

our existing customer base.

“The key for us has been to tool up with

new technology, but then use the savings

generated by the technology to hold our

prices,” he continues. “In effect, we’ve used

technology to absorb and deliver cost-down

initiatives, while enhancing our profitability

going forward. At a time when inflation is

driving up transport costs, materials and

wages, this is a significant selling point

for us.”

The one potential constraint on growth is

the shortage of trained engineers in the

northeast, but Mr Sampy is confident he can

overcome this.

“We are employing two new apprentices

in the summer and we want them both to be

CNC people. But the beauty of Mazak multi-

tasking technology is that it reduces the

reliance on having to find and persuade

highly trained operators to join you.”

OEMs are also taking to 5-axis machining

in their numbers, as demonstrated by

Daventry-based Hi-Force, a manufacturer of

high pressure hydraulic bolting and lifting

products, which has implemented a strategy

to move away from subcontract suppliers.

“The aims were to increase efficiency,

reduce costs and shorten delivery times,”

says Kevin Brown, the company’s managing

director. “The crucial change has been for us

to get ahead of demand from our customers,

despite the 32% growth in our turnover

during 2010. As a result we have invested

around £2 million in manufacturing and

machining over the past two years.”

ONE-HIT INVESTMENT

Among the recent acquisitions is an

NMV5000 DCG 5-axis machining centre from

Mori Seiki (0844 800 7647), which was

purchased to manufacture Hi-Force’s range of

10 torque wrenches – these vary in size and

capacity from 1,700 up to 48,000 Nm of

torque output. The 5-axis capability of the

machine enables the component parts to be

completed in one hit. Furthermore, Mori Seiki

has been providing an ongoing programme of

training and optimisation to enable the

company to produce the complete range of

wrenches and to swap between them

rapidly, as requirements change.

Takers for 5-axis machines are coming

from a diverse range of sources and one

recent trend has seen a string of cutting tool

specialists invest in new models. Among

them is Alcester-based Seco Tools (01789

764341), which has installed a new HPM

600U 5-axis machining centre from GF

AgieCharmilles (02476 538666). The machine

will fulfil a variety of functions, such as: in-

house product and applications training for

staff; undertaking individual customer

projects; and company-organised and

sponsored promotional and educational

events.

“Precision manufacturers machining

complex parts for the aerospace, medical,

oil/gas, power generation and motorsport

sectors are increasingly using and relying on

5-axis machine tool technology to increase

their productivity and improve their

performance,” says Mike Fleming, marketing

and technical manager at Seco. “Many of

these manufacturers are Seco customers.

They use our cutting tools and associated

products, but until now we couldn’t easily

demonstrate or provide customers and

prospects with all the evidence they needed

about our 5-axis technology.”

This strategy is mirrored at another cutting

tool supplier, Halesowen-based Sandvik

Coromant (0121 504 5400), where a new 5-

axis model has strengthened the company’s

prismatic metalcutting capability. The new

DMU50eco from DMG will assist in

demonstrating the latest grades and

geometries of Sandvik Coromant tooling to

customers and will also help in the

development of new milling processes

targeted at specific industries, notably the

aerospace and medical sectors.

One early demonstration has seen ‘rolling-

in’ milling on a 316 stainless steel block,

using a 50 mm diameter face mill and 20 mm

diameter end mill. Trochoidal climb milling,

morph milling (especially of airframe

structures), slice milling and rolling-in

strategies are current areas of focus, in order

to maximise cutter life.

7

MACHINING


GF AgieCharmilles technology at Seco Tools



Vturn-X200 & Vcenter-X300

Evolution. Revolution.

Multi Tasking Mill/Turn Lathes & 4/5-Axis VMCs

A Victor Group Company

Victor CNC has evolved… the same high quality, rugged

construction we are renowned for, but with new, innovative,

high-specification 4/5 axis multi-tasking lathes, vertical

and horizontal machining centres.

Take a closer look today.

t 01706 648485 e [email protected] w victoreurope.com

P008_MCSP_JUN11 23/5/11 07:09 Page 1

Made in Switzerland


Tel: 01780 765965Fax: 01780 765877


The opinion of experts,

the machine operators is

unparalleled and drives the

continued development and

demand for machines like the

milling and drilling machine

Picomax 54 with CNC control

and manual hand wheels.

• Machining of simple parts, for

single/multiple operations.

• Fast and precise manufacturing

of single/small batch parts

• Production of small series

withcontouring programming

THE EXPERIENCE IN PRACTICAL OPERATION

“THE PICOMAX 54

FAST AND SIMPLE

TO SET UP, ENABLES

PARTS TO BE PRO-

DUCED, DESPATCHED

WHILST ALTERNATIVE

MACHINES ARE STILL

AT THE SET UP STAGE“

Sheffield-based Dormer Tools (0870

8504466) is also keen to shout about its

latest acquisition – an FT 4000 5-axis

horizontal machining centre from Heller

Machine Tools (0121 275 3300). The new

machine’s spindle power and high torque

characteristics make it suited to Dormer’s

milling, tapping and drilling demonstrations.

The FT 4000 5-axis will also be used in

Dormer’s customer surgeries – component-

specific demonstrations that help prove the

efficiency of the company’s tools and to

provide optimum advice regarding speeds

and feeds.

REELING IN THE BENEFIT

Of course, 5-axis machining is a growing

trend in almost all Western markets,

including the USA, as demonstrated by Ross

Reels, a Colorado-based fly-fishing reel

manufacturer that has scored enormous

success with its fully machined fly reel,

which is saltwater approved and durable

enough to last a lifetime.

“People thought the owner [Ross Hauck]

was crazy when he launched the business,”

says the company’s plant manager, Larry

Donaldson. “Ross was trying to sell a reel

that cost $150 – probably six times what the

simple stamped and die-cast models of the

day were going for. But, surprisingly to many,

the good-looking product caught on. We now

machine around 27,000 kg of aluminium into

fly reels every year.”

The sport’s demanding customers want

the most satisfying equipment they can get.

High end reels must delight the senses –

they have to look perfect, feel perfect and

sound perfect. And, above all, they must

perform perfectly, every time. While the reels

contain as many as 25 parts, the assemblies

boil down to two basic components: a

stationary frame that attaches to the fly rod,

and a rotating spool that snaps into the

frame. “The frames are the most difficult

parts we make,” says Mr Donaldson.

“They begin as 75-115 mm diameter by 38

mm thick ‘pucks’ of 6061-T6-G aluminium bar

stock. They’re mounted on 5-axis trunnion

tables in one of two VF-2SS Super-Speed

vertical machining centres, supplied by Haas

[01603 760539]. By the time they’re finished,

most of the original material has been milled

away: the billet weighs 1.8 kg going in and

the part that emerges weighs just 0.2 kg.

“Spools also start as aluminium billets,”

he continues, “but they’re initially shaped

and faced on lathes, then transferred to the

mills for the final operations that sculpt their

decorative cut-outs. We machine to

reasonably tight tolerances and really fine

finishes. Standard dimensions are held to

0.05-0.075 mm.”

Ross Reels has now specialised in Haas

technology, with around 14 machines

currently on site.

“For years, we used Japanese horizontal

machining centres to do the frames,”

explains Mr Donaldson. “We figured

horizontals were the best machines to give

us the high productivity and fine finish we

wanted. But, as production expanded, it

became a nightmare to keep the complicated

machines running; they were a well-known

brand, but they were down 50% of the time.

It got to the point where I needed a full-time

maintenance man to keep four machines

going,” he underlines.

By upgrading Ross Reel’s Haas VF-2SS

machines to 5-axis capability, and loaning the

company a Haas TR-160 trunnion table to

develop and test the process, the solution

showed itself.

“The new process saves us 30-50% cycle

time over the old way, and I was able to get

rid of the four big horizontals. We now see

much greater productivity from just two Haas

VF-2SS machines,” says Mr Donaldson.■■

9

MACHINING



Ross Reels upgraded its 3-axis Haas machines to 5-axis


June 2011 • www.machinery.co.uk

�� .−−#∋!�−((%,

0(+−∀�.)�−(�3��

�+��+��(�&∀�%��1#,��#��,�(+��+(�(#∋−��2,−�&,

�∋��+��#/��/(.�∀�+,�0(+−∀�.)�−(�3�� +��&��%�

�!�#∋,−�&�∃(+��.−−#∋!�−((%��+�∋�,��(.�∀�+�/�%.��0#%%

��)�∋��(∋�(+��+�/�%.��

�(+� .%%��−�#%,��(∋−��−�.,�(∋��

(+�/#,#−��

10

Obstruction free 5-axis machining

Universal 5 Axis Vice.

Positive high strength clamping

close to the work piece.

MicronWorkholding

MicroLoc®

Advanced Referencing Workholding Systems

SALES 01480 861321

www.micronworkholding.co.uk

[email protected]

Sole

UK ag

ent

Micron

Workholding LtdMicroLoc®

P010_MCSP_JUN11 23/5/11 10:17 Page 10

FAMAR is the

market leader in theproduction of CNCVertical Lathes, the

dynamics and flexibilityof the organizationenables it to offer aproduct completelycustomized to meet

the needs of the user.

Foundry Road, Stamford, Lincolnshire PE9 2PPTel No. 01780765965; Fax No. 01780765877


11

CADCAM


Softly does itSteed Webzell reviews the current market for 5-axis machining software,

discovering that uptake is more than matching the rate of product

development

Effective CAM software for 5-axis

machining is still relatively young

technology. In the early days, there were

concerns: the tool angle relative to the

selected reference point or surface for the

entire machining area could not be changed,

which made it difficult to avoid collisions; and

rest machining necessitated breaking the job

into several machining steps, significantly

increasing programming time.

One of the biggest stumbling blocks was

complexity of programming. Here, Open

Mind Technologies (01869 290003) says that,

to make program creation as easy as

possible, its hyperMill CAM offers a uniform

interface concept, from turning to 2D and 3D

machining, through to 5-axis simultaneous

machining. This is important, because there

are very few workpieces that require only

one type of machining (2D/3D/5-axis) – the

broad spectrum of strategies grants

flexibility, allowing the user to program many

parts with one type of software.

hyperMill exploits the performance range

of each machine tool and considers

kinematic particularities. Compared to 3-axis

milling, the tool reference point and the

movements of the machine’s linear axes are

different during 5-axis simultaneous

machining, as motion of the rotary and tilting

axes result in ‘compensation’ movements in

the linear axes. The software also enables

users to control the rotation axes

independently of one another, as well as

machining with automatically indexed axes.

And it is benefits such as these that led

Northampton-based GE Precision

Engineering (GEPE) to invest in hyperMill.


Gibbs upgrades 5-axis routines

Gibbs and Associates, developer of GibbsCAM software, says there are many improvements

within GibbsCAM 2011, including several additions and enhancements to 5-axis machining

routines. For instance, there is a new routine for 5-axis hole-making operations, aided by

enhancements to GibbsCAM’s automatic feature recognition, hole manager and hole wizard,

which makes programming 5-axis drill cycles much easier and more efficient.

Also, a new ‘Operation Modifier’ allows converting 2.5 and 3-axis toolpaths for machining in

five axes, which enables use of shorter tools to achieve smoother toolpaths at certain surface

intersections and other geometric conditions. There is also a new 5-axis trimming (wire-frame)

strategy and new support for 5-axis milling on turning machines (using B-axis functionality).

GibbsCAM 2011 is offered in the UK via Tech CADCAM (01284 754781).

Open Mind supports GE Precision’s 5-axis efforts

5axis_cadcam.qxp:Machinery 25/5/11 15:55 Page 11

P012_MCSP_JUN11 23/5/11 07:27 Page 1

In its four years of trading, the company

has invested in several 5-axis machining

centres, including a DMU50 from DMG

(01582 570661), a Mikron UCP600 from GF

AgieCharmilles (02476 538666) and an XR60-

5AX from Hardinge (01162 869900).

However, according to the company’s

managing director, Garry Edwards, the most

important purchase for the 17-employee

business has been hyperMill CAM software,

he affirms.

The selection of hyperMILL occurred

when GEPE was awarded a contract with a

Formula One engine manufacturer to

produce cam covers from solid billets. Mr

Edwards was given a demonstration of

hyperMill at the team, and immediately

realised how easy it was to produce complex

shapes and forms.

“The demo really opened my eyes to the

capabilities of hyperMill, but, most

importantly, how easy it was to program

complex 5-axis forms.

“hyperMILL offers shorter program

lengths, with less code, by condensing

outputs, such as incorporating radii into G2

and G3 codes. It was streets ahead of

anything I had used previously, so the

decision was made immediately,” he says.

The first seat of hyperMill arrived in April

2009, with additional seats following in June

2009 and September 2010.

“Programming times have fallen by

anything from 30 to 60% and, when our

average programming time is approximately

16 hours, it shows how invaluable hyperMill

has become,” says Mr Edwards. “As well as

prototype work, we now have a production

cell machining 40 sets of Norton crankcases

and cylinder heads per week. With its port

machining strategy, hyperMill makes port and

exhaust machining simple.”

Another CAM software specialist,

Delcam, says it, too, has achieved recent

5-axis success at Manchester-based

aerospace subcontractor LSNW (Lofting

Services North West). Here, director Richard

Fielding claims that his company has “no

interest” in simple, high volume jobs,

preferring to take on more demanding work

where other subcontractors would struggle

to compete.

LSNW has invested in Delcam’s

PowerMill, PowerShape CAD and

PowerInspect software suites, plus Delcam

Exchange to read in CATIA models. The latest

and biggest machine tool purchase is a 5 m,

5-axis model. The post-processers for this

machine were written by Delcam engineers,

who liaised closely with the designers of the

5-axis head from ISA, based in Milan.

Further north, at German toolmaker

Formenbau Kellermann, lead times have

been reduced by more than 20% after

investing in VISI from Vero Software (01242

542040), along with a palletised production

process with a zero-point clamping system.

“Pricing pressure, competition from

emerging countries and the trend towards

ever shorter project terms are challenges that

force toolmakers to rethink the traditional

form of single item production,” explains

managing director, Sabine Kellermann. “In

toolmaking, flexibility and the use of the

latest technology is a must.”

The company’s milling department is

equipped with two HPM 1350U and HPM

1850U 5-axis milling centres from GF

AgieCharmilles. One VISI function that is

used intensively at Kellermann is the ability

13

CADCAM

5-AXIS SUPPLEMENT


• CNC-Machining Centres

• Mill/Turn Centres

• Gantry Machines


Tel No. 01780765965; Fax No. 01780765877



Made In Germany

Consistently customer orientated

LSNW has no interest in simple, high volume jobs, and is using Delcam software to support its ambition


P014_MCSP_JUN11 23/5/11 07:27 Page 1


Tel: 01780 765965Fax: 01780 765877


Combined cleaning... (solvent and

aqeous media)

...then

V A I O C SVacuum Assisted Inorganic Organic Cleaning System

Problem

• Continual growing demands in cleanness.

• Parts with organic (oil, grease) and inorganic (emulsion, abrasion) dirt.

• High operation expenses while running two cleaning machines (solvent and aqueous media).

Solution

• With the unique system “VAICOS” it is possible for the first time to apply different cleaning media in one insulation.

No expensive and large-scale recharging

to automatically convert 3-axis to 5-axis

continuous toolpaths. “This enables us to

reduce expenditure on programming time

and still benefit from the advantages of 5-

axis machining,” explains Ms Kellerman.

“For example, the Mikron HPM 1350U

allows for an approach angle from +16° to -

120°, whereby the distance between spindle

and table is only 30 mm. This approach is

applicable for most geometries, and we

benefit from better surface finish through the

use of shorter, more rigid tooling and

reduced vibration.

“The consolidation of high end software

and high end machinery has reduced our lead

times by more than 20%,” she states.

“Those who stand still have no chance in

toolmaking over the long term. Technology

has reduced our costs now and will continue

to do so in the future.”

Another mould tool maker, this time

based on the other side of the Atlantic,

agrees with these sentiments. Ohio, USA-

based Prospect Mold is using WorkNC CAM

software from Sescoi (0844 561 7014) to

optimise 5-axis machine utilisation.

Mould designs are created in I-DEAS NX,

and subsequently every element of the tool

including core and cavity blocks, lifters and

slides, is exported to WorkNC-CAD on the

shop floor.

“The machine operators can turn off

layers to remove water lines, for example,

and do a little bit of surfacing to block ejector

pin holes or fill gaps in the model,” says Mark

Gruic, the company’s data co-ordinator.

“WorkNC CAD does everything we need, is

easy to use, and is completely integrated

with the WorkNC CAM software.”

The company’s 16 operators use the

dedicated 5-axis CNC commands in WorkNC

software for cutting parts such as turbine

blade dies on its seven 5-axis CNC machines.

“We work two shifts, preparing most of

the WorkNC CNC programs during the day

and batch process long calculations

overnight,” says Mr Gruic. “We merge

multiple programs, so that the machines can

run unattended for up to seven hours

overnight or at weekends. WorkNC is

absolutely reliable, enabling us to operate

unmanned with confidence.”

The intelligence in WorkNC’s toolpaths

and its graphical editing are particularly

appreciated by Prospect Mold.

“The amount of time the tool is out of the

material is really low and it stays cutting in

one area at a time, maximising machine

efficiency. We monitor our machine utilisation

levels and we consistently spend 80% of our

time cutting metal. Furthermore, the

flexibility of the toolpath editing is something

which you don’t get with other CNC software

– if you want to change or remove a path,

you can do it very quickly.”

Uptime and reduced cycles are two of the

most important factors for manufacturers

looking for a new CAM package, and it was

with these issues in mind that Halesowen-

based Somers Forge selected NCG CAM

(01223 863911) for shop-floor programming

compatible with SolidWorks (01223 346900)

and the company’s machining centres.

Since introducing CNC machines with

NCG CAM, Somers Forge has had some jobs

reduced from 300 hours to just under 30

hours. The software also allows drilling and

milling on the same machine tool and

eliminates further operations on parts by

using the 3+2 strategy.

Furthermore, when drilling using 3+2,

operators do not need to worry about the

angle of the hole, as NCG says the system

always finds the correct place. ■■

15

CADCAM



Collision checking

CGTech is now shipping Vericut 7.1 CNC machine simulation and optimisation software. Vericut

7.1 features significant enhancements to reduce the time required for manufacturing engineers

to easily develop, analyse, inspect and document the CNC programming and machining

process.

Among the many enhancements, the latest version sees a new feature added for Vericut

collision checking – it is now possible to stop the simulation at an ‘exact’ collision point

between the machine components. While simulating an NC block with the ‘stop at collision’ box

checked, Vericut will stop in mid-motion at each collision point. Clicking the ‘step’ button

continues simulation to the next collision point – or to the end of the motion, if no other

collisions exist.


‘Challenge Dormer’ aims to help businesses save significant

amounts of money and time by offering cost-effective

machining solutions.

To launch the campaign, Dormer is staging open days, on July 5

and 6, where businesses from around the country can visit the

company’s fully serviced productivity centre, located within its UK

headquarters at the Advanced Manufacturing Park (AMP) in South

Yorkshire.

All of Dormer’s partners will

be in attendance at the open

days, including Heller Machine

Tools, Kelch, Open Mind,

Delcam, System3R and

Hexagon Metrology.

Visitors will be able to view

demonstrations of the

machining capabilities of

Dormer’s productivity centre,

including the recently

installed Heller 5-axis FT

4000.

Dormer’s partnership

with fellow global leaders in

the engineering sector is a

further indication of its focus

on milling and threading, in

addition to the company’s

market-leading drilling

products.

Dormer is already gaining

national recognition with

aerospace and automotive companies from around the world for

offering customer-specific solutions, using the new machining

centre to improve manufacturing and process efficiency.

Budding engineers have also benefited from the workshop,

with students from JCB Academy visiting Dormer to build their

knowledge of the machinery and technology being used.

John O’Donoghue, general manager at Dormer Tools, said:

“Dormer’s significant investment in R&D means that our cutting

tools are designed to last longer and work more efficiently,

providing our customers with cost-effective solutions that give

value for money.

“Coupled with the fact that we now have a fully operational

workshop with state-of-the-art machines from a host of leading

organisations, this makes our productivity centre a unique location

in the UK.

“We are confident that with our expertise, and that of all our

partners, we will be able to meet the needs of any application, and

provide our customers with considerable savings – both financially

and in terms of reducing machining hours.

“We encourage companies across the UK to come forward and

put us to the test!”

To attend the Dormer Tools open days on July 5 and 6, between

10am and 7:30pm, in South Yorkshire, or take part in Challenge

Dormer, call 0870 850 4466. Further information at

www.dormertools.com.


Challenge Dormer at national open daysEngineering and manufacturing firms across the country are being invited to put Dormer Tools to the test

16

Advertisement feature

Dormer Tools UK has launched its own Youtube channel to

showcase the company’s productivity centre in South

Yorkshire.

The channel’s latest video showcases Dormer’s

partnership with Heller Machine Tools and the installation of

the new FT4000 5-axis machine.

To watch the video, visit Dormer Tools’ YouTube channel

at www.youtube.co.uk/dormertoolsuk.

You can also follow Dormer’s

Productivity Centre on Twitter –

@DormerPRDcntrUK – and download

the new iPhone App – ‘Dormer Tools

Threadsize Calculator’. This calculates

the drill diameter required to support

precise thread creation.

John O’Donoghue, general manager

at Dormer Tools (right) with Geoff

Lloyd, managing director of Heller

Machine Tools.

P016_Dormer.qxp:Machinery 26/5/11 10:28 Page 16

17

TOOLING AND WORKHOLDING


Well held; well cutWhile 5-axis machining centres grab most column inches, tooling and

workholding requirements are sometimes overlooked. Steed Webzell seeks

to even things up

The optimisation of 5-axis machining

means achieving the correct dynamic

between machine, cutting tool and fixture.

For components that are characterised or

dominated by curves and contours that

require movement in all five axes

simultaneously, only selection of the right

workholding and tooling (with a suitable

constant engagement) will achieve

efficient machining.

Or so says Sandvik Coromant (0121

504 5400), which insists much of the

success of 5-axis machining is in the

preparation. For instance, the way the

cutter is presented to the component

surface is a primary consideration, and

for this reason the lead and tilt angles

should be established as part of the set-

up, using CAM software; not only the

entering angle of the cutting edges, but

also cutter engagement and clearance.

THE RIGHT ANGLE

The lead angle is measured between the

centreline of the tool and the perpendicular

normal to workpiece surface at the point of

tool contact in the direction of feed. In many

cases, this is kept constant, according to

recommendations for the tool, but can be

varied through programming, if the CAM is

capable. Through a locked lead angle, the

cutter is inclined at a predetermined angle

throughout the feed direction, in relation to

the part surface. The angle is established

with reference to the smallest internal radius

on the surface and the effective cutter

diameter, says Sandvik Coromant.

The tilt angle of the cutter is established

in the plane which is perpendicular to the

direction of feed and therefore to the lead

angle; measured between centreline of

cutter and the normal to the surface at the

point of cut. A constant lead angle is

necessary for generating curved and

concave surfaces and, although point milling

consumes more cutting time and tool life,

it’s a secure method to use. Three-

dimensional surfaces are generated by

successive levels of cutters, passes by the

tool engaged with the workpiece at a point

on its corner radius, which varies along the

radius, according to the surface.

According to Sandvik Coromant, flank

milling is more effective in that it has a

shorter cutting time than point milling, but is

more limited in certain respects. For

instance, it is most suitable for semi-finishing

and finishing operations, but only on single

curved or convex surfaces.

Tool selection for 5-axis machining

depends partly on whether point or flank

milling is applied. Flank milling requires tools

with adequately long radial cutting edges,

such solid carbide end mills or exchangeable

head cutters. These can be either straight or

conical and have various corner radii.


Sandvik offers guidance on best practice

5axis_toolingand work.qxp:Machinery 25/5/11 16:12 Page 17


Tel: 01780 765965Fax: 01780 765877


The E Series Concept

Combines conventional, manual

data input and CNC versatility

within one machine and control

system

E30/E40/E50/E60/E70

Innovative Performance

E90/110/120/150/175

Oil and gas industries

• Robust design for precision

and stablility

• Multiple tooling turret options

• Large spindle bores upto

580 mm diameter

• Automated cycles fast and

simple communication

between man and machine

Apprentice, vocational training

• Machining of

simple/complex components

For point milling, there are a number of

tool choices, depending upon the component

features and finish requirements. Generally,

for larger, open surfaces, toroid or bull-nose

type milling cutters are preferred. For

cavities, ball nose cutters are often the best

choice, with conical tools for long overhangs,

where also modular tooling can be provided

and offer reduction adaptors for maximum

stability when tool reach is necessary.

Moving up the shank, away from the

cutting zone, toolholding plays a vital

facilitating role, as the Advanced Engineering

Division of Finecut can testify, following its

researching of options subsequent to the

acquisition of a new 5-axis machining centre

for its mould and die machining operation.

BALANCED APPROACH

Finecut acknowledged that machining at up

to 25,000 rpm demanded balanced, rigid and

robust tooling solutions. CADCAM manager

Danny Welsh reviewed that marketplace and

opted for a Schunk toolholding system.

“Only heatshrink systems could match the

guaranteed 3 micron balanced accuracy of

the Schunk Tribos system,” he says. “This

accuracy is exceptional, considering our

previous collet chucks could only deliver

accuracy of 10-20 micron. However,

heatshrink systems take a long time to reach

the temperatures needed to clamp and

unclamp the cutting tools, whereas the Tribos

can clamp and release a cutting tool

instantly.”

To clamp the cutting tools in the Tribos

holders, the Lancing, Sussex-based company

acquired a Schunk SVP2 pump system for

clamping and unclamping tools, with

corresponding SRE rings to hold the Tribos

holders during clamping.

The SVP pump places a high level of force

on the Tribos S toolholders to create the

elastic deformation necessary.

“The Schunk system arrived within a

matter of weeks of the company acquiring

the 5-axis machining centre,” says Mr Welsh.

“Despite this relatively short period, we

instantly witnessed surface finish

improvements, credit to the 3 micron

accuracy and the improved clamping rigidity.”

Since acquiring the Tribos S system, the

company’s workload has evolved to include

deep cavity mould machining. To facilitate

this shift in strategy, Schunk again provided

the solution, in the form of its Tribos SVL

18 June 2011 • www.machinery.co.uk

B-axis turn-milling

HSK-T is a new derivative of the HSK quick-change spindle interface that is totally compatible

with multi-tasking, turn-milling applications. The key factor with HSK-T is its ability to guarantee

the centre height of a turning tool when being used in a rotating spindle, such as the B-axis found

on many multi-tasking machine tools, with insert position guaranteed to ±0.11 mm on an HSK-T100

toolholder. According to supplier WNT (0800 073 2073), HSK-T provides a new ISO standard in

toolholding for turning applications on multi-tasking machine tools.

“Users of multi-tasking machine tools have been severely limited in their choice of spindle

interface, due to HSK not being available for turning applications. Now, with the arrival of HSK-T,

we are providing customers with a choice of spindle interface that is compatible with existing

HSK spindles they may have on their machining centres, thus creating a more cost-effective

solution,” says WNT’s managing director, Tony Pennington.

Schunk’s Tribos system helps out at Finecut


toolholder extensions, which can be clamped

inside the existing Tribos S toolholders to

enable operators to machine complex forms

inside deep cavities.

With most 5-axis machining in the UK

centring on short batch production, the need

for quick changeover is paramount,

particularly with regard to workholding

technology.

One company meeting this challenge is

Leydon Transmissions of Liversedge, a maker

of power couplings and braking systems for

the yellow goods sector, as well as a provider

of subcontract machining services.

The company’s new managing director,

Mike Robinson, joined in January 2010 and

immediately set about implementing a

programme of investment, starting with a

new £200,000 Doosan 5-axis machine tool

from Mills CNC (01926 736736). He then set

about the process of maximising spindle run

time and minimising set-ups.

“From stopping one job to cutting the

next, our vision is 20 minutes maximum for

any part, including loading any tools required,

workholding and downloading the NC

program. It’s an aggressive target, but an

achievable one, once everything is in place.

QUICK-CHANGE ARTIST

A Hainbuch MS Dock and Mando segmented

mandrel from Leader Chuck Systems (0121

771 4843) addresses the quick-change

workholding demands at Leydon. For a

certain set of quality-critical components, the

company has to locate on the bore of the

parts.

“Starting with round bar stock, we bore a

hole in the middle and then mill it square,

before cross-feed holes are drilled. So, we

have a decent size bore to locate and hold

on, which also acts as the datum,” says

Mr Robinson.

Using the 5-axis Doosan, in combination

with the Leader workholding solution, has

allowed the company to replace what were

six sequential machining operations with just

two – only the back face is accessed after

the cycle has been completed.

“The Leader product is well suited to the

quick changeover ideology: a full mandrel

change only takes three to four minutes.”

Helping to enhance both accuracy and

efficiency even further is palletisation, and

illustrating this point is Northamptonshire-

based Salcey Precision Engineering, a

motorsport component machining specialist

that works regularly to tolerances of +5

micron, with the aid of palletisation from

System 3R (02476 538653).

“System 3R MacroMagnum pallets suit

our requirements perfectly, with up to 18

pallets (each 156 mm diameter) able to be

located on the table of our four Mikron

HSM400 5-axis machines,” says the

company’s managing director, Richard Alcock.

“This gives us the ability to ‘mix and match’

machined parts, together with unmanned

operation – especially as our existing vices

and tombstones can also be accommodated.

“Taking any part off the machine and

measuring it with our CMM is also easily

facilitated. Using our own interface fixed to

the System 3R pallets ensures that positional

accuracy is maintained at all times,” the

managing director adds. ■■

19

TOOLING AND WORKHOLDING


Modular workholding

Triag Precision Tools says that its range of

modular workholding systems brings

particular benefits to 5-axis machining

operations. For instance, the lower base

rails on Triag products serve both as a

mechanical zero-point clamping system, as

well as a vice. Here, all the tension acts at

the workpiece, keeping it rigid – whether

small, long or large – and at the same time

providing high levels of accessibility.

The Triag range offers over 50 different

clamping modules. As well as the raw

‘base’ modules, there are self-centring,

three-jaw chuck, collet chuck and vacuum

clamping modules, to name but a few – and

the interface is always the same.

The range is available in the UK from

REM Systems (01452 314100) and Hilcliff

Tools (01483 266780).


WNT’s HSK-T interface for mill-turn machines



TRIAG precision toolsAussergrütstrasse 2CH-6319 AllenwindenTel. (d+e) +41 (0) 41 727 27 27Tel. (f) +41 (0) 41 727 27 96Fax +41 (0) 41 727 27 99E-Mail: [email protected]

Threading tools

Rem Systems Ltd.Hillcliff Tools Ltd.www.remsystems.co.ukwww.hillcliff-tools.com

tripoxyMINERAL

Epoxy mineral tombstones

powerCLAMP

microCLAMP

aptoCLAMP

mivaCLAMP

oppSystem

triGEL

BAR BY BAR

modular workholding systems

www.amdale.co.uk

22 years of excellence in:

5 Axis CNC Machining

EDM Wire Erosion

CNC Turning

Laser Etching

Units 6/7 Culverin Square

Limberline Road

Portsmouth PO3 5BU

Tel: +44 (0)2392 660726

Fax: +44 (0)2392 655177Quality. Reliability. Customer Service.

Cert No. FM25674

20

PPLIED

UALITY

SSURANCE

SUPPLIERS

TO

F1

The UK Leaders in mobile ON-SITE Calibration with 30 years experience -

1,000 regular customers- 6 Mobile Units +

Laboratory providing...

•On-site calibration service -

including Thread, Torque and Pressure Gauges

•Free record management -

“auditor friendly” & practical

•Automatic recall - via our database

•Ultimate convenience - on your premises

•No delays - avoid duplication of equipment

•Priced to compete with your in-house costs - frequently cheaper

•More time to concentrate on product quality - better use of man-power!

To arrange a visit to discuss your specific requirements, provide a quotation or price list please contact:

Doug Healiss. Applied Quality Assurance Ltd.,Garden House, 25 Bedford Road, Shefford, Beds SG17 5DJTel: 01462 850011 Fax: 01462 850012email: [email protected] web: www.aqacalibration.co.uk

On-site service reaches 30 years

P020_MCSP_JUN11 24/5/11 17:29 Page 20

HORIZONTAL /

VERTICAL LATHES

FOR ULTRA

PRECISION

TECHNOLOGY


Tel No. 01780765965; Fax No. 01780765877



21

INSPECTION


The unexpectedSteed Webzell reports on the latest applications for measuring the features,

geometries and curves created by 5-axis machining

Parts made using 5-axis machining typically

offer complex features or freeform

surfaces and thus measurement often

requires a certain degree of innovation.

Few can testify to this better than

Cheltenham-based Future Advanced

Manufacture (Future AM), a precision

engineering company that recently won its

first significant aerospace contract in the US.

“We can’t say much about it,” says Craig

Peterson, managing director of the AS9100-

accredited company, “except that making

titanium blades for a new propulsion system

requires a very stringent validation process.

Our existing metrology wasn’t up to the job,

so we turned to the Revo 5-axis system.”

Revo from Renishaw (01453 524524) is a

measuring head and probe system that uses

synchronised motion and Renscan5

measurement technology to minimise the

dynamic effects of CMM motion at ultra high

speeds. It also uses Renishaw’s new Modus

software to take full advantage of CAD-

driven programming. The resulting

improvement in efficiency and accuracy has

also enabled the company to offer reverse

engineering services.

First, Future AM laser-scan the

component and turn the data into a point

cloud, which is run through SolidWorks

(01223 346900) CAD and Visi Reverse

software from Vero (01242 542040) to create

a virtual 3D surface. “We then use Revo to

compare the new virtual surface with the

original component to validate possible

engineering processes before making the

cloned parts,” says Mr Peterson.

IN-PROCESS MEASUREMENT

In-process 5-axis measurement solutions are

also proving popula, and a number of

applications are being driven by the

aerospace sector. A case in point can be

seen at Tods Aerospace, which has sites in

Somerset and Dorset. Tods specialise in the

design and manufacture of lightweight

structures in composite materials.

To help maintain its preferred supplier

status for customers such as

AugustaWestland, as well as bid for

increasingly complex 5-axis work, Tods

invested in a 5-axis router from CMS (0115

977 0055), a Renishaw RMP600 wireless

touch probe and OMV Pro measurement


Non-contact inspection of complex shapes

The HN-6060 from Nikon Metrology (01332 811349) is a next-generation, non-contact inspection

system that uses an advanced laser scanner, 5-axis synchronised hardware control and ultra

stiff design to inspect complex shapes, including gear teeth and turbine blades.

The HN-6060 captures high density 3D point clouds from part surfaces at a rate of 120,000

points per second and to an accuracy of 5 micron. A new laser scanning sensor extracts the

surface form and waviness data in one scan, whereas previous tactile gear inspection tools

relied on 2D sections of data. A core element of the HN-6060 is its 5-axis synchronised

hardware control. This gives optimum part orientation to the sensor, allowing it to measure from

different angles.

Renishaw’s Revo in action at Future AM

5axis_Inspection.qxp:Machinery 25/5/11 16:23 Page 21


• Highest holding force lowest clamping pressure

• Save on material wastage clamp securely on only 3mm

• Full 5 face machining no clearance issues

• Repeatable positioning of material better than 0.01mm

• Self centring accuracy ±0.02mm

• Reversible clamping jaws for larger range

• Clamping ranges 0 to 355mm

• User friendly for short tools

• Precise strong design

• Competitive Price

For more information and a Demo call

THAME WORKHOLDINGField End, Thame Road, Long Crendon, Aylesbury, Bucks HP18 9EJ Telephone: 01844 208050 Fax: 01844 201699 Email: [email protected]

THE ART OF 5-AXIS WORKHOLDING

LOCKED IN PERFORMANCE

22

Call: 01543 478710

Click: www.hainbuch.com

Manual stationary chuck MANOK plus

Massive clamping force, easy to use

Ideal for 5-Axis machining

Accurate, fast, easy set-up

with pull back action

Can be used with all HAINBUCH

adaptations and clamping heads

MANOK plus RD with clamping

head

MANOK plus RD with jaw adapter

[clamp up to Ø 120 mm]

MANOK plus RD with

mandrel

MANOK plus RD horizontal

set-up [with through-bore]

P022_MCSP_JUN11 27/5/11 10:56 Page 22


Tel: 01780 765965Fax: 01780 765877


PowerJet Flood cleaning

system

Utilising

environmentally

friendly aquas

solutions

Customer benefits

• Modular structure with compact design.

• Multi stage spray, flood, immmersion process.

• High swarf removal PowerJet action.

• Rotation or oscillation with programmable angle.

• Drying by hot air/vacuum.

software. The RMP600 is a compact touch

probe, which incorporates Renishaw’s

patented Rengage strain gauge technology

and uses frequency hopping spread spectrum

(FHSS) radio signal transmission.

“One of the key reasons for purchasing

the probe was to align the cabin roof

of the AugustaWestland AW159

Lynx Wildcat and then machine it,”

says CNC manager Bob Young.

“This has proven very successful

and we are now producing our

own CMM reports, generated from

the use of the Renishaw OMV

software and the RMP600 probe. Without

the probe, we would not have been able to

machine the roof as accurately and we

couldn’t have aligned the jigs with such

precision.”

Blurring the line slightly between online

and offline 5-axis inspection systems are

portable CMMs: technically speaking, an

offline device, but one that can be walked to

the machine tool, if required. If the

application dictates, there are real gains to be

had here, as Coventry Prototype Panels

(CPP) can confirm. CPP specialises in the

prototyping and low-volume manufacture of

vehicles and components, such as the

Spyker Aileron – the firm builds 200 a year.

Some of the solutions offered by CPP vary

from traditional component prototyping to

what can almost be considered metallic arts,

looking at some of the contours achieved.

The company utilises measurement

technology from Faro (02476 217690) to

ensure the parts correlate to design

specifications. The Faro ScanArm uses laser

technology to inspect parts quickly, including

on the production line, should the need arise.

CPP expertise in this area has also led to

it being awarded the contract to supply Aston

Martin with parts for its million pound sports

car, the One-77.

Sports cars and motorsport vehicles are

big business in the UK, from Formula One to

amateur stock car racing. When the Brunel

Racing team from Brunel University was

seeking to improve its results in the annual

Formula Student championships, it knew

getting the Yamaha R6 engine fitted correctly

into the rear chassis space frame was one of

the most time-consuming.

The task involved gaining an accurate

measurement of the complete engine,

which, with its complex geometries, is

no easy task. A CMM might measure

a few points accurately, but to gain an

accurate picture of the entire surface

could take weeks. Meanwhile, a laser

scanner requires an expert operator and

may also entail a lengthy process to ‘patch’

individual scans together.

WHITE LIGHT SAVES TIME

As a result, Brunel Racing approached 3D

white light measurement specialist Phase

Vision (01509 839000), whose equipment

undertakes scans in a matter of seconds,

using sine wave technology that projects a

series of light stripes on to the object and

uses an integral camera to develop a

complete visual representation, based on

millions of points. “Having the engine

scanned cut around three weeks out of the

design process, meaning we will have longer

to test the final vehicle,” says Matt Carey,

powertrain manager for Brunel Racing.

Ralph Weir CEO of Phase Vision adds:

“This project is a further example of how

detailed scanning can create accurate virtual

representations of highly complex

components which can be manipulated using

CAD and so save both time and cost in the

final manufacturing process.” ■■

INSPECTION


Hexagon’s new Cognitens technology at work


New white light device

The introduction of the manual measurement system Cognitens WLS400M and the automated

Cognitens WLS400A replace all former white light products from Hexagon Metrology (0870 446

2667). White light measurement uses digital stereo vision technology to generate highly accurate

3D data. “The new product generation comes with innovative LED technology, stable carbon fibre

housing and a compact system set-up”, says Duncan Redgewell, Hexagon Metrology’s vice

president portable products.

5axis_Inspection.qxp:Machinery 25/5/11 16:25 Page 23

P024_MCSP_JUN11 27/5/11 10:54 Page 1

Documents

The Magazine for Production Engineers JUNE 2011journal-download.co.uk/digitalmagazines//my/my02jun2011fullmy.pdf · The Magazine for Production Engineers JUNE 2011 SPONSORED BY