The retrofit of a three-axis control system to a bed mill has solved a number of problems for a specialist manufacturer of aluminium gravity diecasting machines.
The retrofit of an Anilam MK 3300 three-axis control system to a Butler Elgamill bed mill has solved a number of problems for Auto Gravity Machines, the specialist manufacturer of aluminium gravity diecasting machines.
Not only has the new CNC rejuvenated the ageing machine tool, but the system has also eliminated the need to sub-contract certain large workpieces and, as a result, generated all-round improvements in productivity levels.
Proprietor, Jim Sills, explains: "We bought the Elgamill about a year ago.
Although it is quite old, it is a very well-built, rigid machine.
It wasn't initially purchased with the retrofit in mind, but the fact that it had DC stepper motors and recirculating ballscrews - which, of course, are the basic requirements for a successful retrofit - meant I immediately recognised the potential for a future upgrade.
"This, I reckoned, would in effect covert on old workhorse into a modern CNC machine at relatively low cost." He continues: "Until we installed the machine, we were restricted in terms of machining capacity.
However, with X, Y and Z axes travels of 1800mm by 900mm by 1000mm, the Elgamill now enables us to machine large workpieces, such as C frames, in a single set-up.
"This capability has eliminated the need to re-position workpieces often two or three times on the table of our existing (smaller capacity) milling machine - or, if we could find a suitable sub-contractor, outsource the work.
"Because we operate two other CNC milling/machining centres, we recognised the advantages of upgrading the Elgamill in terms of both improved control functionality and speed of machining.
"Since the machine was being used with an Anilam DRO (hard-wired into the original control), and we found that very easy to use, we naturally leaned towards an Anilam CNC.
Also, we had received good reports of the system from a number of users (customers and peers) and, compared with alternative control suppliers, the Anilam option was very cost-effective.
These were all major factors in our choice of control." The retrofit was carried out by CSD Controls (UK), an Anilam-approved CNC retrofitter, and simply involved removing the DRO, building a new console and hard-wiring the MK 3300 into the existing panel.
Most of this work was completed by CSD off-site, to minimise machine downtime.
The PC-based Anilam MK 3300 control combines user-friendly conversational programming (Machinist Language) with digital signal processing for high-speed data processing and motion control.
The control features a range of canned cycles, including: * Irregular pockets - a simple routine of prompts produces clearances of shapes; * Geometry - the geometry calculator, for determining points, lines and circles, automatically forms the program foundation; * Bolt hole pattern and drill cycles are created by simple question and answer routines; and * Graphics - program verification with user-friendly graphics and program text and CNC status displayed together.
"The whole project went very well," comments Jim Sills.
"And we immediately found the MK 3300 a user-friendly, easy-to-program system - albeit we have only used the machine on straightforward two-axis milling, drilling and boring tasks." Since its establishment in 1967, Auto Gravity Machines has supplied machines for a variety of applications, but predominantly the automotive industry.
Although each machine is designed and manufactured for a particular task - proprietary parts are bought-in but everything else is machined/fabricated at the site in Aylesbury, Bucks - they can be successfully applied to subsequent workpieces.
Whatever the component, the company deals mainly with the foundry, working its designs around the size and requirements of the die, often utilising clever hydraulics/pneumatics for progressive die orientation.
"Achieving a successful diecast component is akin to pouring a glass of Guinness," adds Jim Sills.
"If the aluminium is 'tipped' in from too high, then a lot of dross and oxides are produced on the surface.
But if the metal is poured gradually, there's less inclusions/porosity/air entrapment and, generally, less metal is used.
The result is a higher quality component.
"The Elgamill is now a key machine in our production process," he concludes.
"Thanks to the Anilam CNC our new-found medium and heavy-duty milling capabilities have improved our overall machining efficiency and our lead times.
In turn, this has also cut our costs - and that's a good thing for both us and our customers.".
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