With five linear axes and two C-axes, another
beneficial feature on the Tornos DT26 was
the integrated 20 bar pressure coolant
facility with a high-pressure air blast. “Having
such features integrated into the Tornos as
opposed to optional extras reduced both the
machine cost and footprint. The combination
of a smaller footprint machine with integrated Tornos Active Chip Breaker (ACB) system for
lights-out machining. Referring to this, Mr
Hutcheson says: “We’ve only ever run day-shift
machining, but now we have the Tornos and
its ACB system, we can look at unmanned
running. At present, the DT26 has halved our
production times and freed capacity of the
turning centre that was running the gear
features and the soluble oil aspect had swung
us towards Tornos. We preferred the Tornos
DT26 for these aspects but it was also the
ease-of-use, machine kinematics, simple
set-up tooling configuration and also the
fact that Tornos are very local from a service
perspective that sealed the business.”
The machine instantly slashed the cycle time
of the Ertalyte TX plastic gear components
from 50 to 25 seconds per part, taking more
than seven days off the previous monthly
production schedule. Additionally, the facility
to work with and without he guidebush has
reduced material consumption and with a
changeover time in the region of 15 minutes,
the customer can rapidly switch between
modes to suit each batch run. Historically,
Kenson has only operated on a single 8-hour
shift basis; however the Tornos DT26 has
been supplied with the 3m barfeed and the project. Additionally, the DT26 has replaced
an ageing EMI-MEC automatic turning centre
and comfortably absorbed all the work the
EMI-MEC was previously machining. For
example, the production of 2,000 small rollers
on the EMI-MEC machine would take 3-4 days;
the Tornos produces four rollers a minute,
meaning the job is finished in a single-shift.
This machine was also dedicated to producing
3,000 spacers each week for electrical
cabinets; we now produce these parts on the
Tornos at least 50% faster than ever before.”
The Tornos DT26 has completely changed the
way the subcontractor schedules its work, as
Mr Hutcheson says: “We have a monthly order
for 2000 nylon conveyor belt parts with a
previous output of 400 parts a day; this would
tie-up one machine for more than a week per
month. The Tornos can do more than 1000
parts a day, so we will produce 6000 in a week
and hold the quarterly stock for the customer.
There are many examples of how the Tornos
has more than halved cycle times, however
the key aspect is that the machine has freed
capacity from all our larger turning centres.”
Kenson Catches a Winner
Kenson is building its confidence towards
lights-out machining. When the company
targets round-the-clock running, the Tornos
is likely to improve throughput and capacity
availability significantly on all machines.
As the first turning centre with a twin-
spindle, the DT26 has reduced cycle times
on more complex work. Referring to this,
Mr Hutcheson says: “We were apprehensive
about the step to a twin-spindle machine
but the Tornos TISIS software really simplifies
the process. TISIS allows us to do a simple
program for the main spindle and another
program for the sub-spindle, once we have
these foundations in place, TISIS prompts us
to fill-in the remaining movements between
the spindles. Furthermore, the machine
operates with a FANUC 31 Series CNC control
unit that is familiar with all our machinists.”
The sub-spindle operation has improved
precision, consistency, surface finishes
and overall component quality whilst the
TISIS system has simplified programming
processes. However, it is a smaller feature
on the DT26 that is saving considerable time
for Kenson - the part-catcher. “Plastic swarf
is often long and stringy and without a part-
catcher on our other machines, small parts
would drop into the machine sump, leaving
staff in a rescue attempt to redeem parts from
the swarf. The Tornos DT26 efficiently collects
the parts and puts them into a bin outside
the work envelope – it’s surprising how much
of a difference some of these peripheral
features can make to the everyday life of the
machinist. We’re delighted with the Tornos,
it’s been a great addition to our facility,”
concludes Mr Hutcheson.
Web: www.tornos.com
Issue 34 PECM
139