Breakthrough in lean and agile machining realized

Citation

(2001), "Breakthrough in lean and agile machining realized", Aircraft Engineering and Aerospace Technology, Vol. 73 No. 3. https://doi.org/10.1108/aeat.2001.12773cab.008

Breakthrough in lean and agile machining realized

Breakthrough in lean and agile machining realized

Keywords: AMTRI, Machining, Automation

The completion of the ground-breaking SHIMM machine (single hit multifunctional machining), now fully operational at AMTRI's Macclesfield, UK, site, is the fruit of a four-year, E6 million, EU research project with partners from Germany, Italy, Sweden and the UK. The goal was to produce and evaluate prototype SHIMM systems that allow multiple processes to be integrated on a single work station and thereby enable complete component manufacturing, with minimum setting and non-productive times.

SHIMM is believed to represent the ultimate application of that cardinal rule of automation that says, "grip the part and don't let go until it is finished". SHIMM machines are not "universal" – indeed they are "lean" and agile. Lean machines can be configured rapidly and cost-effectively from only those processing modules required to complete the types of part envisaged. This same modular approach confers agility as it means that machines and manufacturing solutions can be reconfigured and adapted as requirements change (plug and play for modules, as AMTRI describe the process).

In this way it is thought possible to meet the challenge of the trend towards smaller quantities, shorter product life cycles and shorter time to market.

Besides having defined advantageous process combinations and researched and developed the technology for integrating and operating processes effectively within a single workstation, the project has seen two prototypes designed and built. An early prototype was evolved by SMT from an existing lathe design and the second, an AMTRI prototype, was purpose-designed in parallel with specific modules from each of the project partners.

These demonstrators are being used to conduct integrated research into technical and economic performance, operation and support technologies. Issues already addressed include: configuration/reconfiguration methods for both hardware and software; rapid alignment methods; part program proving and collision detection (all in reconfigurable machines with up to 13 axes).

AMTRI's machine is equipped with twin head stocks, to allow machining on all sides, combined with full-function milling capability. The BSA headstocks have direct drive with C-axis capability. A three-axis gantry carries either a fixed Chiron spindle for three-axis (+C) work, or a JOBS spindle with tilt/rotate for five-axis work. The gantry also carries the beam-guides for the 2kW Ferranti CO₂ laser. Twin independent cross slides mount two Duplomatic turrets, one with provision for driven tools, either of which can be substituted by a Boneham & Turner grinding spindle.

The new machine provides a novel UK resource for module development and process and operation research. It has already been used by Birmingham University to assess the potential of laser-assisted machining for a new aerospace material on behalf of Rolls-Royce.

SHIMM project partners were: AMTRI, BSA Tools Ltd, BT Products AB, Chiron Werke, Ferranti Photonics, Gebr. Helier, IVF, IFW, JOBS SpA, Sandvik Coromant AB, SMT, and WZL Aachen.

Details available from: AMTRI. Tel: +44 (0) 1625 425421; Fax: +44 (0) 1625 434964; Web site: www.amtri.demon.co.uk