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Product category: Machinery and Production Equipment
News Release from: Matchmaker M/C | Subject: Mitsubishi M-H5B horizontal machining centre
Edited by the Engineeringtalk Editorial Team on 19 June 2002

Change of attitude boosts machining
performance

The introduction of a high speed horizontal machining centre has worked wonders for one Lancashire-based subcontractor.

The introduction of a high speed horizontal machining centre has worked wonders for one Lancashire-based subcontractor For the installation of a Mitsubishi M-H5B horizontal machining centre, supplied by Yamazen (UK), has enabled T and R Precision Engineers in Colne to reduce production times, be more competitive, extend its machining capability and secure a number of contracts it could not have economically quoted for in the past

Specialising in precision machining and small assembly work for the aerospace industry, T and R Precision Engineers used to rely solely on vertical machining centres for its milling capability.

Since a management buyout in July 1998, the company has adopted a much more progressive investment strategy in order to win new business and improve manufacturing performance.

This has seen seven new VMCs added to the existing six units at the company's Lowther Lane works since 1999.

However, managing director Ray Maddison and his management team realised the potential of bringing in a high-speed horizontal machining centre for much of its complicated work.

And in May last year the company installed the twin-pallet Mitsubishi M-H5B machining centre.

"We knew that on quite a number of complex aerospace projects, changing attitude from vertical to horizontal spindle working would bring us significant benefits", says Maddison.

"And such a switch would also enable us to quote for new business where we were just not competitive enough in the past, re year on year price reductions The combination of multi-fixturing, reduced set-ups, pallet changing and faster machining means that on the right sort of work the Mitsubishi can be up to five times faster than a vertical machining centre.

While it is still early days as yet with the machine, we are looking to save up to 50% in terms of setup and cycle time on jobs which have been transferred from our vertical machining centres".

The M-H5B horizontal is being run on a three shift basis to provide round-the-clock working, five days a week.

Employing 65 people, T and R produces a wide range of precision components for the aerospace industry, with around 75% of its work for the civilian sector.

Much of this work is destined for critical areas of the aircraft such as undercarriage, thrust control boxes, control pedals, wing structures and engine reverser/nacelles.

Most of these components are machined from aluminium alloy, stainless steel and titanium and batch sizes typically range from 1 to 15 off, although certain parts are required in their hundreds.

Tolerances are down to around 0.002mm and the company runs an SPC programme and uses CMMs to ensure conformity.

When T and R eventually decided to bring in a horizontal machining centre, it drew up a short list of suitable machines in terms of size, power, rigidity, speed, build quality and cost.

And after a thorough assessment of the market, it decided that the Mitsubishi M-H5B best met its all round requirements.

This machine has a 12,000rev/min spindle (although there's a 20,000rev/min option), 60-station ATC, 40m/min rapids, 22kW AC spindle motor and a working envelope of 650 x 650 x 650.

Tool and pallet changing times are 1.3 and 5s, respectively.

Among the most complex components currently being produced on the Mitsubishi are locking system elements machined from solid blocks of aluminium alloy.

Measuring up to 559 x 381 x 90mm and required in batches of 12 off, these 'A' frame style parts require extensive profiling, pocketing, drilling, boring, deep recessing and surface blending operations on five faces.

Quite a large percentage of the material is removed from the original billet to produce this intricate form.

In trials on a vertical machining centre it took almost 25h and numerous setups to produce these locking elements.

However, the M-H5B horizontal is now producing these components in under 5h.

Two 'A' frame parts are mounted on the fixturing cube at a time and only four setups are required.

Smaller parts are also being far more effectively machined on the Mitsubishi.

Required in batches of over 500 off, these 203 x 76mm aluminium blocks are multi-fixtured (up to 16 at a time) to further optimise machining cycles.

T and R is also producing some stainless steel components on the horizontal, too.

For example, various landing gear elements, fuselage reinforcing sections and door brackets are now being machined some 40% faster compared to the cycle times previously achieved on vertical machining centres.

Surface finish (a major consideration on aerospace work) has also been improved, too.

There's no doubt that the M-H5B has made a big impact on production efficiency at T and R, as Maddison concluded.

"While we have still to fully exploit all the benefits of the Mitsubishi, this four axis machine has made us more productive, competitive, flexible and has expanded our all round production capability.

We also tend to look at things in a different way now as the introduction of this high speed machining centre has marked a step change of thinking throughout the company".

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