SUBCONTRACTING
<
Mould tool
methodology
Five years after setting up vertical machining centre was solid rather than source raw
their mould tool making installed some 18 months ago castings to retain complete
business Dave Bowyer and and, according to Mr Bowyer, control of the production
Steve Riddle took delivery of ‘is providing the versatility and process. By not having to wait
their first CNC machine tool. reliability that we need’. for raw castings to be
A ProtoTrak turret mill was the Founded in 1992 and located delivered, the company reports
first of several CNC/manual in the historic Somerset town of it can save up to 48 hours –
mills and lathes to be supplied Bridgwater, Sterling Products which is vital as it is often
by XYZ Machine Tools. specialises in the design and working to tight deadlines.
However, Sterling Products’ manufacture of moulds used to Prototype moulds machined
latest investment is a full CNC vacuum form plastic packaging from model resin are used to
XYZ 1010 VMC equipped with for a wide range of industries. produce sample packaging in-
Siemens 810D ShopMill control. The seven strong company house, which is then submitted
The 15kW (20hp)/8,000rpm opts to machine moulds from to the customer for checking
Sterling Products' Dave
and approval. This process Bowyer displays a typical
includes ensuring that vacuum aluminium production
formed food containers, for
mould that has been
example, when stacked prior to
finish machined on the
use can easily be separated,
XYZ 1010 VMC UIforward
and transit trials to check that
individual containers and their
contents can be stacked
securely and transported tool change time (tool to tool)
safely. Once a packaging and features extra wide
design has been finalised, a hardened and ground box
production mould can then be slideways for maximum rigidity
machined in aluminium. and vibration absorption. X, Y
"Having a machine with the and Z travels are 1,010mm,
capacity of the 1010 VMC 504mm and 540mm
allows us to load, say, a dozen respectively, with rapid feed
workpieces on its 1,200mm by rates of 24m/minute on all
450mm table, download the three axes.
required programs and then Simple conversational
run the machine unattended programming of the Siemens
overnight and at weekends," ShopMill control ensures the
says Mr Riddle. "We come in to minimum of operator
find that the job, which may keystrokes, with canned cycles
involve machining several catering for common machining
Supply Chain Excellence for identical moulds for one functions such as contour
all your Gear and Transmission
customer or any combination of pocketing, and no need for G
moulds for several customers, coding knowledge. Checking
component projects
has been completed and the everything is correct before
machine has turned itself off. machining is equally simple:
This is how we stay competitive the control features a line trace
Gibbs Gears Precision Engineers Ltd
Units 3 & 4 Triangle Business Park, t: +44 (0) 1296 739020
and maintain our business at a view and a simulation package
Quilters Way, Stoke Mandeville f: +44 (0) 1296 739039 comfortable size." that allows the operator to see
Bucks,
sales@gibbsgears.com
The 1010 VMC’s 24 station exactly what is going to be
HP22 5BL
www.gibbsgears.com
toolchanger has a 2.5 second machined before pressing the ‘Cycle Start’ button. with seven years service and
Having been introduced to another is in his first year as an
CAD/CAM at an XYZ open day, apprentice, attending day
anything other than relatively release at Bridgwater College.
TRIED AND TESTED...
simple moulds or general "The practical side of mould
Surface heat treatment techniques
machining work is making has been made less
have been successfully employed for over
programmed offline. Using a difficult in recent years with the
80 years.
network link from the PC to the wider use of CAD/CAM and
machine, programs can be CNC machine tools," says Mr
Flame Hardeners Ltd. has over 60 years’
copied to the control system’s Bowyer, "and the ease with
experience in applying these processes to
internal storage or executed which the XYZ machines can be
engineering components, both
directly from the computer’s programmed and operated is a
large and small.
hard drive. And rather than case in point. However, mould
The skills, experience and expert advice
store NC programs, the original tool making is still a very
of our material treatment specialists
model information is kept on demanding discipline and one
ensures accuracy and repeatability of
file to provide the basis for new where there is an increasing
processes, backed by
programs that take account of requirement for more
• rigorous quality control and
any subsequent design tweaks. academically-based
assurance procedures
Ex-apprentices themselves, knowledge."
• hardness testing and
Messrs Bowyer and Riddle are
NDT examinations
firm believers in the
• metallurgical testing
apprenticeship system and
have helped a number of
Why not put us to the test
young people over the years to
• gears up to 4.5dia. gain engineering skills and
• shafts & rollers up to 1.5m dia.
experience. One of the current > XYZ
and 7.5m length
team is a former apprentice
www.xyzmachinetools.com
• machine beds up to 6m length
• wheels up to 2.3m dia.
Visit our
new website:
FLAME HARDENERS LTD - INDUCTION HARDENERS LTD
Shorter Works, Bailey Lane, Sheffield, S1 3BL T: 0114 276 8167 F: 0114 273 8657
www.pesmag.co.uk
28 March 2010 • Production Engineering Solutions
www.pesmag.co.uk
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