Ward CNC Hankook Lathe Cuts Cycle Times By 50% For Scottish Sub-Contractor
Turning long, complex profile components for the ceramics industry previously caused headaches for Scottish precision sub-contract machinist, Dunblane Light Engineering.
The two-operation process required separately turned parts to be screwed together to create the finished product. A long-bed machine was the obvious answer and, after narrowing the choice down to two machines, the choice was a Hankook Protec 7NB two-axis horizontal lathe from Ward CNC of Sheffield.
As a result, the 3,000 mm between centres Hankook has transformed the process into a one-hit sequence and cut cycles times by around 50 per cent!
Dunblane Light Engineering has an impressive client base centred on a number of industries such as North Sea oil, petro chemical, glass and ceramics. "It's true that we wanted a long-bed machine specifically for one of our customers in the ceramics industry, but general demand was growing at a rate that meant we needed more capacity anyway," says managing director Andy Trombala.
"We were looking for a machine with 3,000 mm between centres, which obviously narrows the market," he continues. "However, we managed to find two machines we were keen on, and the attention that Ward CNC gave the project provided me with the confidence I was looking for. I knew I was in safe hands and that should any after-sales support be required, Ward CNC would be more than happy to help."
The machine has been deployed on the long-term contract the company has with its customer in the ceramics industry. "These are long, large components," says Andy Trombala. "They are also parts that demand a competent control system, which was another factor in selecting the Hankook. We are not talking about shafts with two or three shoulders, these parts feature complex radii and profiles with high surface finish requirements.
"However, we needed to hit the ground running and didn't want a machine that would require extensive operator training. It had to be user-friendly and simple to program."
The Hankook Protec 7NB features a Fanuc 21iT CNC and dual electronic handwheel control, which combines the accuracy and productivity of user-friendly CNC turning with the simplicity and versatility of a manual machine via dual electronic handwheels; thus enabling users to quickly move into productive mode since minimal CNC training is necessary.
That Ward CNC could supply the Hankook Protec 7NB ex-stock was another factor in the machine's favour. And though the ex-stock machine came with a manual toolpost, Ward CNC soon retrofitted an indexable toolpost to match DLE's requirements.
The Hankook Protec 7NB has a swing over the bed of 750 mm, a swing over the carriage of 480 mm and a maximum turning diameter of 750 mm. Distance between centres is 3,000 mm and maximum turning length is 2,900 mm. Spindle speeds of 3 to 1,000 revs/min are attainable and maximum traverse rates are 3 m/min and 6 m/min in X and Z axes respectively.
It features double-walled and ribbed one-piece meehanite cast iron bed, and induction hardened and ground precision slideways.
"The machine has been a revelation," explains Andy Trombala. "The lathe that it replaced was getting long in the tooth and as it only had 1,500 mm between centres, it meant that the manufacturing process for these particular components was problematic. We had to turn two separate parts and screw them together, but now the parts can be made in one hit on the Hankook, cutting cycle times by approximately 50 per cent.
"Also, I no longer have to live in fear of the old machine letting down what is one of our major customers. I'm delighted with both the Hankook machine and the service provided by Ward CNC."
SOURCE: T W Ward CNC Machinery Ltd