Latest News Archives - Whitehouse Machine Tools

New Robotic Systems For Automating Machine Tools

wmtcnc — Tue, 11 Jun 2024 08:59:37 +0000

A new range of storage and handling systems for loading and unloading machine tools automatically has been introduced to the UK and Ireland by Whitehouse Machine Tools, Kenilworth, in partnership with the Turkish manufacturer Tezmaksan.

CubeBOX robotic cells are suitable for automating virtually any make of CNC lathe or machining centre, including those that Whitehouse markets (Biglia, Brother and Spinner), as well as other types of machine tool.

Robot operation is non-stop, resulting in close to 100% OEE (overall equipment effectiveness) of the machining cell, which is unattainable if machine tending is performed manually. Higher productivity and reduced lead times are the result. Fast loading and unloading of workpieces into and out of up to three machines enhances flexibility and agility, enabling quick adaptation to changing production requirements.

A Brother 30-taper machining centre being automated by Whitehouse Machine Tools with a Tezmaksan CubeBOX robotic system for loading and unloading components.

Amortisation of an investment is rapid, as the operator only needs to load billets, castings or forgings into the workpiece magazine and unload the finish-machined components. The person is therefore free to carry out other added-value tasks elsewhere on the shopfloor. Additionally, unattended ghost-shift production is possible, contributing further to profitability and allowing manufacturers to compete more effectively in a competitive global marketplace for machined components.

Cell integration and robot programming are said to be particularly easy. Connection to any make of machine control system is possible, eliminating the need for customisation or modification. The process therefore does not rely on a skilled integrator. The high degree of compatibility simplifies and lowers the cost of implementation. Downtime is minimised during installation and commissioning, which normally takes one day, reducing the expense associated with prolonged setup periods.

The foundation of all CubeBOX systems is RoboCAM, an intelligent, 2.5-axis CAD/CAM automation software developed by Tezmaksan. Operators can effortlessly integrate any compatible industrial 6-axis robot into the cell, without the need for prior programming knowledge. RoboCAM translates any uploaded 2D product drawing into a robot-friendly language, enabling seamless communication and execution of automated cycles.

The flexibility of CubeBOX allows its easy transportation between different machine tools within a factory. Such mobility ensures optimal utilisation of the system across various workstations, eliminating the need for separate robotic setups for each machine. The versatility empowers manufacturers to streamline their production efficiently, optimising resource allocation and floor space.

A Brother 30-taper machining centre with a Tezmaksan CubeBOX robotic system for loading and unloading components.

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Major Upgrade to Large 30-Taper Machining Centre

wmtcnc — Thu, 27 Apr 2023 14:54:39 +0000

Brother, the Japanese 30-taper machining centre manufacturer, has had a machine in its portfolio with a one-metre X-axis for nearly a decade. The third iteration of this model, launched in April 2023, has seen the specification uprated in several key areas to boost capacity and versatility. Sole sales and service agent in Britain and Ireland is Whitehouse Machine Tools, Kenilworth (www.wmtcnc.com).

Now called Speedio W1000Xd2, the machine is the largest on the market and best in class in the 30-taper category. Extension of Z-axis travel from 300 to 380 mm together with the new option of a 250 mm column extension means that a much larger component may be placed under the spindle. If it is rotated in a trunnion, swing diameter is increased to 540 mm and if it is fixtured directly on the table, maximum weight is 500 kg.

Brother Speedio W1000Xd2 – the largest on the market and best in class in the 30-taper category.

A benefit of having 1,000 mm travel in the X-axis is that either long components may be machined, or else a pair of smaller parts side by side. In the latter case, if they are undergoing Op 10 and Op 20, one comes off completely machined every time the doors open. Alternatively, multiple small parts may be placed under the spindle for many hours of uninterrupted production.

Typical applications are to be found in the electric vehicle manufacturing industry for the production of, for example, a battery control box, chassis component or instrument panel. Other target markets are the semiconductor and mould making sectors.

Users processing tool steels will benefit from the introduction of a 10,000 rpm / 26.2 kW / 92 Nm high-torque spindle option in place of the standard 12,000 rpm offering. Another option is a 16,000 rpm face-and-taper contact spindle. Through-coolant at 435 or 1,015 psi is available on request. With the encroachment of these 30-taper machines into the 40-taper arena, the high-torque spindle has been endowed with increases in spindle bearing diameter, spindle clamping force and tool retention force, increasing metal removal rate by typically 50 percent.

Previously available with 14 or 21 tools, the machine is now offered with the new option of a 28-pocket magazine. It leads to a reduction in machine downtime due to less frequent tool replenishment when a series of complex components are being machined. Likewise, metalcutting can continue uninterrupted for longer with the use of sister tools, maintaining high productivity regardless of the production mix.

Brother Speedio W1000Xd2 table size and travel dimensions.

Maximum tool length and diameter are now 250 mm and 110 mm respectively and weight has increased to 4 kg. Chip-to-chip time is 1.5 seconds even when the heaviest tools are deployed in the 28-tool magazine, while if lighter tools are mounted in one of the smaller magazines, it is just 1.3 seconds.

Compared with a 40-taper machining centre, the 3.35-tonne W1000Xd2 is exceptionally environmentally-friendly. The machine draws only 20 percent of the power due to energy saving measures, which include LED lighting, high efficiency pumps, auto-off functions and power regeneration from the high efficiency motors.

Moreover, due to the agility of axis motions and the fact that the very fast linear rapids up to 56 m/min take place simultaneously with tool change, the high productivity often enables one Speedio to do the work of two ponderous, 40-taper machines. In that case, energy consumption is an order of magnitude lower.

The CNC-D00 control has a modern graphical user interface, many apps and support functions to assist the operator and up to 3 GB of memory. Tool centre point control with up to 1,000-block look-ahead and fast processing ensure excellent surface quality on the machined components

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5-axis 30-taper VMC aimed at 40-taper market

wmtcnc — Mon, 20 Feb 2023 17:02:30 +0000

30-taper vertical machining centre (VMC) manufacturer Brother, Japan, has introduced a new 5-axis model with a swivelling rotary table, the Speedio U500Xd1. Despite having a nominal footprint of just 1.5 x 2 metres, it is capable of multi-face machining of components up to 500 mm diameter by 270 mm high and weighing up to 100 kg.

Combined with a 28-position magazine for tools weighing up to 4 kg and either a 10,000 rpm / 18.9 kW or 16,000 rpm / 15 kW spindle with a face-and-taper interface option, the production centre redefines machines in this class and is squarely aimed at competing with 40-taper machining centres. 30 or 70 bar through-tool coolant is available.

Sole sales and service agent in Britain and Ireland, Whitehouse Machine Tools (www.wmtcnc.com), points out that there is little competition to the machine on the market in terms of its sheer speed of operation. Rapid traverse is 50 m/min in X:500 mm and Y:400 mm and even faster in Z:300 mm, which accelerates at 2.2 g up to 56 m/min. Chip-to-chip time is 1.3 sec, or faster still if a 14- or 21-tool magazine is fitted. Cutter exchange and axis motions take place simultaneously to minimise cycle times.

Trunnion swivel (A-axis) at 50 rpm is a generous -30 / +120 degrees and the table (C-axis) rotates at 75 rpm. Roller gear cam mechanisms drive both rotary axes and 0-90 degree indexing times are 0.9 sec and 1.2 sec respectively. Clamping torques are high at 610 Nm and 500 Nm.

Lowering the power consumption of its machines has long been Brother’s aim. For a start, the electricity and air used by a 30-taper machine is only about 20 percent of that required by a 40-taper machine. In addition to having a low inertia spindle and highly efficient spindle motor, the U500Xd1 is equipped with a power regeneration system that reuses energy generated when the spindle motor decelerates. Other energy saving measures include efficient filtration that limits the size of the pump needed, a low energy LED work light with automatic off function, automatic coolant off, standby mode and automatic power off.

Control of the machine is by Brother’s latest CNC-D00 with 15-inch LCD touch panel, offering extended look-ahead and enhanced usability. The home screen displays the total and remaining cycle time, workpiece counter, remaining tool life and shortcut keys, without having to scroll through a menu. Support apps have been incorporated to give an overview of production and operational status, load monitoring, power consumption, tool set-up and adjustment, recovery support and cycle time optimisation.

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New Cell Demonstrates Automated, High-Speed Production of Mill-Turned Components

wmtcnc — Thu, 03 Dec 2020 16:43:50 +0000

Speedio 30-taper, 3- to 5-axis machining centres built by Brother are able to produce components in such short cycle times that it is difficult to load raw material and unload finished parts by hand quickly enough. So to maximise production efficiency, the Japanese machine manufacturer introduced a robotic handling system, Feedio, at the EMO machine tool show in 2017.

Now an automated cell comprising both products is available for demonstration in the Kenilworth showroom of sales and service agent, Whitehouse Machine Tools. It is designed to show to British and Irish manufacturers the suitability of the configuration for unattended and overnight running in high volume production environments.

A Speedio M300X3 trunnion-type, 5-axis mill-turn centre has been chosen to demonstrate the benefits of the Feedio automatic load / unload system. The machine is able to perform prismatic and rotational metalcutting in one hit within a 300 mm by 440 mm by 305 mm working volume.

Notable features include a BIG-Plus face-and-taper contact spindle that accelerates from zero to 16,000 rpm in 0.2 second, a -30 to +120 degree tilting table axis, high output turning capability that generates a maximum torque of 102 Nm and rotational speeds up to 1,500 rpm from zero in less than 0.3 second, and a Brother control with increased memory for holding multiple programs.

When milling, up to 30 m/min cutting feed rate maintains a high level of productivity and 400 Nm of C-axis clamping force ensures that accuracy is maintained. Non-productive time is minimised by repositioning the X, Y, Z, A and C axes simultaneously during tool change, which takes place in 1.5 seconds chip-to-chip.

To extract the most from the high productivity that this specification offers, the machine is linked to a Feedio component storage and robotic handling system developed jointly by Brother and ABB. The plug-and-play, retrofittable automation is able to serve either one machine, or alternatively two to enable op 10 and op 20 machining of prismatic parts on six sides.

The automation unit is designed specifically for Speedio machines rather than being a generic solution provided by a third party. It communicates with the machining centre control via a Profibus interface. A smart ABB teach pendant incorporating a customised Speedio page is provided for programming the 6-axis robot.

Having a handling capacity of 10 kg or 20 kg, it can be equipped with standard grippers or an adjustable double gripper. A camera and built-in PC allow the robot to detect where on the upper inlet conveyor a billet, casting or forging has been placed. After machining, components are returned to an output conveyor positioned below the first. Options include a static station for regripping a component, a turn-around station, and equipment for deburring, washing, air cleaning and marking.

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Plastic Injection Moulder Upgrades Toolroom

wmtcnc — Wed, 21 Oct 2020 17:37:41 +0000

It was as recently as 2012 that manual plus two-and-a-half-axis CNC milling gave way to full 3D machining of plastic injection moulds on a 3-axis vertical machining centre (VMC) at family-run toolmaker and plastic injection moulding specialist Plasticom Group (www.plasticomgroup.com). Since that time the toolroom has undergone a transformation, with 2020 alone seeing investment of £250,000, mainly for the purchase of a Sodick die sinker and a German-built Spinner 3-axis VMC from UK sales agent Whitehouse Machine Tools (www.wmtcnc.com).

Arrival of the latter machine at the end of September 2020 coincided with the departure of a 25-year-old CNC milling machine. It fell to toolroom coordinator Ian Alexander to investigate the best replacement for it. Three were considered and the Spinner was selected due to the comprehensive specification of the standard version of the manufacturer’s VC750.

It includes linear scales, 22-bar through-spindle coolant, a swarf conveyor, Blum TC52 spindle probing, 24-station BT40 tool magazine, 12,000 rpm spindle, Siemens drives with up to 36 m/min feed rate and the latest Sinumerik 840D control with 24-inch Industry 4.0 multi-touch display. Mr Alexander estimated that the equivalent package from other suppliers would have cost half as much again.

He said, “The VMC represented the best value for money by far and the latest Siemens control is a real bonus. It allows us to program cycles to produce complex forms directly at the machine, taking the load off our CAD/CAM department.

“We also like the rigid, cross-table, C-frame design, which results in superior cutting performance and component geometry. The ability to probe a part before it comes off the table and re-machine it if necessary is a big time-saver and makes us more competitive.

“The Spinner is between 30 and 70 per cent quicker than our other VMC, depending on the type of component. I should say it halves cycle times on average due to faster axis movements, the extra rigidity which allows heavier cuts to be taken without causing vibration, and the latest Siemens control.

“It offers so much more productive capacity that there will be a lot of spare time to take on additional subcontract machining, which at present accounts for only a few percent of turnover.”

Operating from a factory of nearly 20,000 sq ft in Ashford, Kent, Plasticom has longstanding, high profile customers including household names such as StanleyBlack&Decker, Games Workshop, Qualcast and Swann-Morton, as well as a host of smaller firms that call on its services. It was invited in March to be part of the UK government’s Ventilator Challenge UK consortium and staff worked long hours under considerable pressure to ship 15,000 plastic ventilator parts to McLaren Racing to a very challenging schedule.

The company is accredited to ISO13485:2016 and has a class 7 clean room for assembly of medical devices. Its plastic injection moulding capacity utilises machines rated from 20 to 530 tonnes, including automation, and extends to twin-shot moulding and overmoulding. Manufacture of press tools, vacuum forming tools and die casting tools also forms part of its remit, while other services include ultrasonic welding, blister and other packaging techniques, laser welding and printing.

The 60-years-established company is owned by chairman Edwin Simmonds and his wife, Sonia, group finance director. Ms Simmons commented, “More than four-fifths of the injection mould tools we make are used in-house to produce a very wide range of parts for customers, a side of the business that accounts for a similar proportion of our turnover.

“Keeping the moulding section operating is therefore crucially important to us, so we look to our machine tool suppliers to provide prompt after-sales back-up.

“The service that we have received so far from Whitehouse has been fantastic, both in terms of the technical input and the training.

“Our shop floor staff have had one week’s tuition so far but no limit has been placed on the amount we will receive in the future, free of charge, which is unusual and a great reassurance.”

Mr Alexander has adopted a policy of buying in bolsters from Meusburger to allow Plasticom to concentrate on 3D milling and sparking of tools. A fixture sits permanently on the table of the Spinner VC750 so that each new bolster can be clamped quickly prior to machining of mould inserts within the 760 x 460 x 460 mm working envelope, which is large for the machine’s 2.6 x 1.7 metre footprint.

He also advised that dimensional tolerances down to a few microns are routine and the surface finish achieved is “fantastic”. In aluminium as well as Stavax, a mirror finish can be achieved using standard, mid-price, carbide end mills and considerably less polishing is needed overall.

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New 5-Axis Machining Centre from Germany

wmtcnc — Thu, 08 Oct 2020 11:31:22 +0000

Featuring a generous working volume of 815 x 510 x 510 mm in a small 2.5 x 1.8 metre footprint on the shop floor, the new VC850- 5A is the latest prismatic metalcutting machine to be launched by German manufacturer Spinner Werkzeugmaschinenfabrik, whose factory is located near Munich. The 5-axis, vertical-spindle machining centre, which is configured with a +110 / -5 degree swivelling trunnion carrying the rotary table, is available in the UK and Ireland through sole sales and service agent Whitehouse Machine Tools, Kenilworth (www.wmtcnc.com).

Managing director Tim Whitehouse commented, “This is a top-end machine with robust rotary axes, which are normally the weak point in 5-axis machining. They are driven by a new planetary gear train and are fitted with absolute rotary scales instead of incremental encoder feedback.

“We are also impressed by the additional clamping plate beside the table that allows Op20 as well as Op10 to be programmed into a single cycle for one-hit machining. The option of a rotary hydraulic supply for automatic workpiece clamping is a further benefit, as it introduces the possibility of automation for long periods of unattended production.”

The 5-tonne machine has an FEM- optimised, cast construction that provides a high level of rigidity and vibration damping for elevated cutting performance and high standards of surface finish on machined components up to 200 kg. Further advantages are that tool life is extended and accuracy of machining is enhanced.

Part of the reason for the machine’s compactness is the patented method for protecting the saddle’s Y-axis guideway from swarf and coolant ingress using
a single wiper system, eliminating the need for a telescopic cover. The depth of the machine is consequently shorter, leading to a 30 per cent reduction in the area needed for installation. The X-axis guideway also has a single wiper, allowing the table to move to the extremes to simplify automated loading and unloading from the sides.

Powerful, high-speed spindle options are 12,000 rpm SK40 / BT40 or 18,000 rpm HSK63, both rated at approximately 18 kW and offering 86 and 57 Nm of torque respectively. They are served by a 32-pocket tool magazine, although a 40-station version is available. Rapid traverse in all linear axes is 40 m/min to minimise non-cutting times.

High pressure coolant delivery at 22 or 70 bar may be specified to assist chipbreaking when cutting difficult alloys and to encourage swarf evacuation, which is in any case assisted by two spiral augers feeding the chip conveyor.

Further choices are in-cycle workpiece and tool measurement, mist extraction, various tooling packages, and linear scales to replace the large-diameter ballscrews in the orthogonal axes to, providing absolute positional feedback to match that of the rotary axes.

The Spinner VC850-5A is equipped with the latest generation of Siemens control, Sinumerik One, which features software for the creation of a corresponding digital twin of the machine. Technology functions help improve processing speed, contour accuracy and workpiece quality. In the second quarter of 2021, there will be the option of a Heidenhain TNC620/TNC640 control instead.

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5-Axis Spinner U5 cuts machining cycles from 45 minutes to 8 minutes

timw — Tue, 25 Jun 2019 10:32:48 +0000

Traditionally a 3-axis vertical machining centre (VMC) user, Singer Instruments (www.singerinstruments.com) in Watchet, on the north coast of Somerset, installed its first 5-axis CNC machine – a Spinner U5630 – at the start of 2019 to streamline the manufacture of aluminium components.

Cycle time savings have been dramatic and there has been a considerable reduction in the number of set-ups needed across a raft of different parts.

Download Singer Instruments Case Study

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New agent for WELE in the UK and Ireland

wmtcnc — Wed, 04 Jul 2018 14:33:13 +0000

Whitehouse Machine Tools has been appointed, with immediate effect, sole agent to sell and service in the UK and Ireland the full range of machine tools manufactured by WELE Mechatronic. You can view the complete WELE range here.

Founded in 2007, the Taiwanese firm produces vertical and horizontal machining centres with X-axis strokes up to 2,500 mm, B-axis and trunnion-type 5-axis machining centres with up to four metres travel in X, large bridge-type mill-turn centres with capacities up to 16 x 5 x 1 metre, horizontal borers, and both horizontal- and vertical-spindle turning centres.

Tim Whitehouse, Managing Director of Whitehouse Machine Tools, Kenilworth said, “We are delighted to represent WELE and its wide portfolio of machines, which have won numerous awards at international machine tool shows.

“The group’s product range greatly enhances Whitehouse Machine Tools’ offering to British and Irish manufacturers and dovetails neatly with machines from our other principals.

“They include Japanese 30-taper turret machine producer, Brother; German machining centre and lathe manufacturer, Spinner; Taiwanese builder of mid-capacity machining centres, Averex; Italian CNC turning centre manufacturer, Biglia; and machining centre, grinder and automation system provider, Toyoda.”

One of the latest new products to be introduced by WELE is the AA1165 vertical machining centre. It is a powerful, high accuracy machine that has undergone extensive hand scraping and offers a working volume of 1,100 x 650 x 600 mm.

Mr Whitehouse mentioned that the first one has been sold to a market‐leading manufacturer in the UK of split valves for the pharmaceutical industry, complete with a tailstock and Kitagawa 4th CNC axis. Another has been ordered for stock at the agent’s Kenilworth showroom and technical centre. View the complete WELE range here.

The robust construction of the AA1165 3-axis VMC manufactured by WELE.
(Click to enlarge)

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Spinner VC1650 – Compact, Heavy-duty 5-axis Machining Centre

wmtcnc — Thu, 09 Nov 2017 13:04:29 +0000

Anyone needing to machine complex components weighing up to two tonnes within an 820 mm cube may wish to review the new VC1650 5-axis machining centre from German manufacturer, Spinner, represented in the UK and Ireland by sole agent Whitehouse Machine Tools, Kenilworth.

Rigidity and accuracy are assured by deploying a +1°/-110° B-axis spindle to provide the fth CNC axis, avoiding having to swivel the rotary table. A xed table to the right of it allows workpieces up to 1,650 mm long to be supported horizontally for 3-axis metalcutting, extending the machine’s versatility.

The spindle head centreline is o set by 200 mm to the left of its centre of rotation to allow features closer to the table to be machined.

Notable also is the patent-pending method of protecting the table’s Y-axis guideway from swarf and coolant ingress using a single wiper system, eliminating the need for a telescopic cover. The depth of the machine is consequently shorter, leading to a 30 per cent reduction in overall footprint.

As the table moves to the extremes in the X-axis, automated loading and unloading from the sides is simplified. Another characteristic of the machine is FEM-optimisation of the cast structure, which provides a high level of rigidity and vibration damping for elevated cutting performance and high standards of surface finish on machined components. Further advantages are that tool life is extended and accuracy of machining is enhanced.

A user can choose from a vast array of alternative features and options, such as a 464 Nm high-torque spindle or a 18,000 rpm high-speed spindle, a 96-pocket magazine for SK50 / HSK100 tools or 138 pockets for SK40 / HSK63, 70 bar high-pressure coolant instead of 22 bar, linear scales in X, Y and Z, and either a Siemens 840D sl control with Spinner’s 24-inch Touchpanel 4.0 interface or a Heidenhain TNC640 with 19-inch screen.

Often overlooked when drawing up a machine tool shortlist is the aspect of chip disposal. Spinner has optimised efficiency in this area by providing four spiral augers to deliver chips to a conveyor at the front of the machine for convenient removal. It also ensures negligible heat transmission and allows space on the shop floor to be saved when installing the 16-tonne machine.

All Spinner machine tools are manufactured in its Munich factory. The medium-sized enterprise has delivered more than 20,000 since its inception in 1950 and currently sells in excess of 1,000 CNC machines per year.

See the Spinner VC1650 5-axis machining centre in action on YouTube.

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Compact, high performance machining centre from Germany

timw — Tue, 08 Nov 2016 12:00:17 +0000

A new, vertical-spindle machining centre has been introduced by the German manufacturer, Spinner, which despite having a generous working envelope of 1,650 x 820 x 820 mm, occupies a relatively small footprint on the shop floor of 3,550 x 2,750 mm.

Its compactness is a result of employing a novel method for protecting the 1,800 x 820 mm table’s X and Y axis guideways from swarf and coolant ingress using a single wiper system and without recourse to telescopic covers.

Designated VC1650, the 3-axis machine joins the smaller VC1150 model with 1,150 x 620 x 600 mm travels introduced two years ago. Both machines are available in the UK and Ireland through sole sales and service agent, Whitehouse Machine Tools, Kenilworth. An informative video showing the VC1650 in operation and giving representative cutting data may be viewed at: www.youtube.com/ watch?v=Pbi6I_rtLg0

Another notable characteristic is the 14.5 tonne, FEM-optimised cast structure, which provides a high level of rigidity and vibration damping for elevated cutting performance and high standards of surface finish on machined components. Further advantages are that tool life is extended and accuracy of machining is enhanced, assisted by optimal chip evacuation via a conveyor at the front of the machine which ensures negligible transmission of heat.

The distance from the operator to the front of the table, which accepts components weighing up to two tonnes, has been minimised to 200 mm for convenient workpiece loading and unloading without strain. Operator convenience is extended further by the ability to adjust the control panel height and keyboard angle.

The machine is nimble despite its size, with rapid linear traverse in X, Y and Z of 48 m/min. Options available on the machine are a 32 or 60 tool magazine; a choice of Siemens 840D SolutionLine, Heidenhain TNC620 / TNC640 or Fanuc 32iMB controls; and an SK40, SK50 or HSK63 spindle with speeds from 8,000 to 18,000 rpm and power / torque up to 62 kW / 343 Nm.

There are numerous other opportunities to customise the Spinner VC1650. Further equipment that can be supplied include a rotary table, coolant mist suction unit, high pressure coolant delivery (22 or 70 bar), hydraulic workpiece clamping, workpiece and tool measurement, glass scales and various tooling packages.

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