5-axis machining brings new opportunities for precision engineering firm

Since its formation in 1979 Newcastle Tool & Gauge (N.T.G.) has adapted to change. Originally a toolroom manufacturing press tools for local industry it has evolved into a precision engineering machine shop.

Along the way it has gained an enviable reputation as a preferred supplier to customers across a wide range of industry sectors, including oil and gas, power generation, subsea and thermoforming. As its customer profile continues to change, so does its requirements for machine tools and during 2018 it identified a requirement for full-simultaneous 5-axis machining.

“We have a varied mix of CNC machining centres, turning centres, grinding and wire erosion machines, but we knew that 5-axis had to be an integral part of that mix. A group of us visited MACH 2018 with the brief to look at every 5-axis option. We all came back from that trip of the same opinion, that the XYZ UMC-5X was the right option for us,” says Mark Withycombe, operations manager.

Among the key features that drew the team to this conclusion was the use of a trunnion table that provided the weight carrying capacity needed as well as the ease of access for loading. Overall build quality also impressed, especially when matched to a highly competitive price.

The next step was to see the machine in action being demonstrated on parts that reflected the materials machined at N.T.G., such as Inconel, stainless steels and other exotics. The demonstration held at XYZ Machine Tools’ Burlescombe showroom were carried out on a UMC-5X equipped with Heidenhain iTNC 640 HSCI control, as this was familiar to the engineers at N.T.G. However, side by side was another UMC-5X equipped with the Siemens 840DSL Shopmill control. Seeing this in action was a ‘lightbulb moment’ for the N.T.G. team.

“We have broad experience of a number of control systems but having seen how easy the Siemens was to program and the overall user-friendliness of the control the entire team pushed for that option,” Mr Withycombe explains. “All that was left was to specify the rest of the machine to suit our needs which included a 60-position toolchanger and the 15,000rpm in-line spindle.”

With the machine now installed the initial expectations of the team at N.T.G. are being fully met, with the build quality and accuracy of the XYZ machine helping to reduce cycle times. One particular job that would normally have taken six operations to complete, is now down to two and cycle time has been halved.

“The move to 5-axis simultaneous machining with the XYZ UMC-5X is a first for us and it has definitely opened up new opportunities, with the capability of the machine allowing us to machine parts that we couldn’t have considered before,” comments Bryan Larvin, works manager. “This is the first machine we have had from XYZ and from what we have experienced in terms of support we would certainly consider more when the time is right to invest.”

The XYZ UMC-5X is a simultaneous 5-axis, gantry style machine that provides high performance at a highly competitive price point. Standard features include a direct drive 90rpm C-axis table configuration, combined with ±120° on the tilting A-axis, with 2.5 seconds for full movement.

With the table tilted 90° towards the rear (component facing forward), there remains 500mm of Y-axis travel forward of the table surface, allowing larger workpieces to be machined. Axis feedrates are 36m/minute in X, Y and Z with travels of 600mm in X and Y (500mm in Z) to maximise use of the 600mm diameter table.

Standard spindles are in-line direct drives with 35kW of power and either 12,000/15,000rpm, an option to go to a 25kW, 18,000/24,000rpm motorised spindle is also available.

The UMC-5X also features Traori/Kinematic functions during 5-axis simultaneous machining for improved accuracy, high accuracy Heidenhain linear scales on the X-, Y- and Z-axes and similar super high specification rotary scales on rotating B- and C-axes.

Additionally, the machine features built-in thermal growth compensation and integrated systems for improved productivity, including tool-tip positioning control, spindle vibration supervision, dynamic collision monitoring and smart machining technology.

XYZ Machine Tools www.xyzmachinetools.com