News

Having acquired a large capacity VMC, and oil and gas industry components supplier can now cost-effectively machine 2.5m long workpieces in one set-up

Nexus Precision Engineering has acquired a large capacity Hartford Sumo vertical machining centre (VMC) from Ward CNC to cost-effectively machine 2.5m long workpieces in a single set-up. The 3m bed capacity VMC features an integrated fourth axis and right-angle machining head, as well as 60-tool auto toolchanger.

Project manager at Nexus' Broxburn (Edinburgh) site, Paul Rafferty, said: 'The whole concept of Nexus' operation has been to identify niche requirements then source machines to satisfy them.

And the deal with Ward CNC of Sheffield was no different - we saw an opportunity and we invested appropriately in a machine that was fit for purpose'.

Nexus employs 40 to manufacture a wide range of components - including undertaking a certain amount of assembly - to satisfy a 'blue chip' customer base in the UK and Singapore.

Nexus supplies a variety of workpieces for oil and gas work, and in particular, downhole tooling to companies such as Baker Hughes ProductionQuest, FMC and Schlumberger with The Hartford Sumo was purchased primarily to satisfy the need for the one-hit machining of downhole gauge carriers for Baker Hughes ProductionQuest.

Required in batches of two-/12-off, currently on average 15/month are being supplied.

Made from 4140 or 420 stainless steel, these are received by Nexus as offset bored and honed 'blanks' in a variety of sizes from 100mm to 150mm diameter and from 1800 mm to 2.5m long.

Once the journals are turned (within the dedicated cell built around the Hartford machining centre and a lathe ) each carrier enters the Hartford Sumo for a series of milling and drilling routines.

Routines include component-length slot production, to tolerances of +/-0.05mm using bull nose cutters.

Nexus then completes premium (licensed) threading before pressure testing.

'The key to the success of the Hartford Sumo, apart from its extra long bed capacity, is the integrated fourth axis and right-angle head,' said Rafferty.

'These features enable all prime machining operations to be performed in a single loading - there's no second operations and therefore no inter-operation handling to extend lead times and overall costs.

The machine is the ideal solution'.

He continued: 'When the opportunity came along to machine these parts, we obviously looked at other machines but quickly decided on the Ward CNC solution because of the capability it offered and the fact that it was a tremendous value-for-money package.

It was also supplied with Fanuc-based CNC, which offered a degree of uniformity across the shopfloor'.

* Open-fronted design VMC - of open-fronted design, the construction of the Sumo 3100 AG VMC is based around a cast iron frame with hardened and ground box slideways.

It has a table of 3100 by 1050mm able to accommodate 4,000kg workpieces, and X, Y and Z travels are 3050mm by 1016mm by 1070mm.

As standard, the 18.5/25kW spindle produces speeds of 50 to 6,000 (optionally 8,000) rev/min (pulley-style - 40 to 4,000/6,000 rev/min geared).

The BT 50 taper machine is supplied with a 20- (optional 32- or 40-) tool automatic toolchanger.

* Reduced programming times - running the Sumo 'around the clock' on a two-shift basis, product manager Mark McLellan said the Hartrol-Fanuc AI100/0iMC programming package is especially useful.

The Hartrol advanced functionality programming routines consist of a series of easy-to-use cycles designed to simplify and speed up programming times and therefore reduce downtime along with other useful setting and maintenance functions for ease of operator use.

These routines include, for example, the following.

* workpiece datum setting using edge setter.

* Manual tool setting using calibrated setting block.

* Tool magazine tracking (for arm-type ATC).

* Tool logging.

* Spindle load monitor.

* Full M Code listings.

* Comprehensive set of special canned cycles.

The Hartford Sumo is also allowing ISO 9001:2000 accredited Nexus to gain additional cycle time reductions by the use of new tooling, said Ward to manufacturingtalk.com.

The VMC also has the ability to run existing tooling at faster speeds.

McLellan said: 'For example, we can now utilise carbide inserted FMR (fast metal removal) face mills of 50-63mm diameter at 3,000 rev/min spindle speeds compared to 1,000 revs/min, and at feed rates of 3000mm/min compared to 500mm/min.

This is making a massive contribution to shorter cycle times.' Rafferty concluded: 'Like all our investments, the new machine was justified on the basis of volume of orders, and the buoyancy of the market in terms of future projected loading.

We partner our customers in the true sense of the word - beginning with dedicated key project/account managers to offer a personal service with a single point of contact.

On this basis we are able to make calculated decisions regarding all machine installations, which have totalled around GBP 2 million during the past three years'.

With annual turnover forecast to reach GBP 6 million during the next four years, it is clear that since the company was established in 1997 Nexus continues to build a successful business in the oil and gas industry.

Ward CNc said that there's also no doubt that investment in the appropriate machining technology is central to that success.