Batch time cut from one week to one weekend

Citation

(2005), "Batch time cut from one week to one weekend", Aircraft Engineering and Aerospace Technology, Vol. 77 No. 5. https://doi.org/10.1108/aeat.2005.12777eab.004

Batch time cut from one week to one weekend

Batch time cut from one week to one weekend

Keywords: Machine tools

Further upgrading existing Walter tool and cutter grinder programs with another machine from Walter GB of Redditch – a 5-axis Helitronic Power with Disc Loader – has helped Mercian Cutting Tools (Tamworth) slash batch times for solid carbide milling cutters from one week at single shift staffing levels, to just one weekend unattended.

“Although we still get good service from our older Walters we knew we could make gains through the acquisition of a new machine that would allow unattended tool manufacture”, says Mercian Director, Andrew Lawrence. “Deployed correctly, lights out production has the potential to double the working week.”

Mercian already had three Walter Power-type machines (the first was purchased in 1996) so the Redditch- based company was the natural first port of call when a new machine was being contemplated.

“I did consider other suppliers, but we get excellent support from Walter and this is vital because we simply cannot afford to have machines go down. On the rare occasion I need assistance from Walter, I never have to wait long.”

Mercian has more than 30 years' experience designing and manufacturing cutting tools, predominantly for the aerospace, automotive and medical markets. Tool types include carbide drills and reamers with multi-steps (either solid or through coolant), milling cutters (solid and bore type), TCT milling cutters, TC slug reamers and countersinks, and HSS sub-land drills.

Installed in November last year, Mercian's latest Helitronic 5-axis Power with Disc Loader is already running full tilt and performing to a high standard. It was supplied with a Production Package for enhanced performance – uprated spindle to 24 kW, glass scales for all linear axes and 6/20 bar dual pressure coolant pump.

“Some of our multi-step tools have step lengths tied to within ±0.025 mm”, says Andrew Lawrence. “If a tool has three steps, it doesn't leave much margin by the time we machine the third step, due to the effects of accumulative error. However, the Helitronic copes with these tolerances”.

Mercian has also taken the option of an automatic hydraulic centre, which is used as a study on extra long reamers.

The 5-axis Helitronic Power is a sturdy machine weighing in at 4.5 tonnes for unsurpassed rigidity and stability. It offers rapid traverse rates of 15 m/min in all linear axes and 120°/s on the rotational axes. The machine can accommodate tools up to 350 mm long (300 mm for face grinding) and 320 mm diameter. The disc loader will accommodate 40 tools up to 160 mm long and 32 mm in diameter.

“In terms of the Disc Loader we generally set this up with 40 tools at 5 p.m. most evenings and leave the machine to run overnight unattended and continue over the weekend.”

“Typically, a batch that previously took us a week to manufacture on a single shift, can now be produced over a weekend, lights out.”

Details available from: Walter GB Limited. Tel: +44 (0)1527 60281; Web site: www.walter-aq.de