Boosting machining capability
Boosting machining capability
When faced with a pressing need to boost machining capability to fulfil a new contract for aircraft wheels and brakes, it was the rapid response of DMG UK along with the high specification of the GMX500 linear turn-mill centre that proved decisive for a UK, Midlands-based subcontractor (Figure 6).
One of the largest parts it manufactures is the torque tube, which is supplied to the company as an investment casting made from high specification titanium. “We needed to invest in a new machining facility in order to meet the schedule and achieve the required output,” explained a spokesman.
Figure 6 The GMX500 linear turn-mill centre from DMG UK Ltd
“Although the casting is as near net shape as possible, it still has many critical features that require machining to tolerances in the realm of 0.025mm (from a material that is very difficult to cut) such as bores, milled flats and tapped holes,” he continued. “Added to this difficulty was the fact that the project timescales involved were extremely tight so we also needed a machine on a short lead-time. Without a new machine we would be faced with much higher component flow costs”.
Having made some initial enquiries the subcontractor found that only two machine tool suppliers could meet the lead-time requirements, DMG and a Japanese competitor. However, it soon became apparent that the GMX500 from DMG was the clear favourite.
The GMX500 with its twin spindle, twin turret configuration enables the company to machine the torque tube complete in a single set-up, a facility that would not have been possible on the competitor's machine. Its automated pallet changer also allows a much higher throughput reducing cycle time massively.
The GMX 500 linear turn-mill centre features rapid traverse rates of 70m/min and acceleration of 1g, making it ideal for up to six-sided rapid machining of complex parts for industries such as aerospace. It is equipped with two compact 45kW spindle motors that deliver high metal removal rates through 1,080Nm of torque. The combination of a 12,000 rpm milling spindle with integrated face serration and a 12-station star-revolver round off the features of this impressive turn-mill centre.
At the time of order, the GMX500 destined for the UK was built, assembled and ready- to-ship from the Gildemeister headquarters in Germany. Despite, the fact that the company required a minor modification to the machine's fabrication in order to accommodate the torque tubes more effectively it was still delivered,installed and commissioned within the deadline. Recently, the GMX500 is dedicated to the manufacture of torque tubes and runs for 24 h, four-days a week and single shift on Fridays.
The investment in this machine was particularly significant as it was the subcontractor's first DMG purchase and a move away from known technology. It continues to meet the high-component specification comfortably and is now seen as being a major asset in the company's strategy to win contracts against fierce competition from low-cost economies.
Details available from: DMG (UK) Ltd; Tel: +44 (0) 15 82 57 06 61; Fax: +44(0) 15 82 59 37 00.
