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supplies the automotive, medical, pharmaceutical, hydraulics, research and general manufacturing sectors, machining anything from 25 to 50,000 parts on its turning centres. “We manufacture simple to complex parts for a variety of sectors and our machine shop reflects this flexibility,” Mr Underwood explains. “We have 63mm diameter capacity fixed head turning centres that offer rigidity and flexibility on large parts and we have two 32mm diameter capacity sliding head lathes for anything from simple to complex parts in batches from 25 to 5,000. However, the introduction of the 20mm capacity Tornos Delta offers us an additional dimension. We have a number of small and relatively simple parts in the 3mm to 20mm diameter range and although our sliding head lathes can machine the parts, they’re not ideal.”
This is highlighted by one of the first jobs that Restormel transferred from its sliding head centre to the Delta 20/4, as Mr Underwood recalls: “We had an order for 30,000 spacers and started machining them on one of our 32mm sliding head machines. However, when an urgent job came in for the 32mm machine we transferred the parts to the Delta. The Delta cut the cycle time from 30 seconds to 21, showing it was clearly the ideal machine for the job. “The reduced cycle time was a combination of faster sub- spindle operation, faster rapid rates and the compact work envelope that keeps the cutting tools close to the component to minimize non-cutting time during the cycle. This combination improved productivity by 30% on this one job. At this point, it was evident we had bought the ideal machine for our business.” This instance highlighted that the 32mm capacity machines were not the most efficient solution for the smaller components at Restormel. “The 32mm and 63mm machines are too big, rigid, robust and overloaded with features that are irrelevant for our small part production,” Mr Underwood affirms, “whereas the Tornos Delta is a highly productive solution that offers simplicity on every level. The Fanuc control and the Tornos integrated bar feed are among the simplest I have operated, meaning the machine really did hit the ground running.”
He continues: “So far the Tornos machine has been
dedicated to six component types that include spacers, copper electrodes and spool extensions, delivering exceptional cycle times and component quality. We are now looking at costing our jobs differently since the arrival of the Delta. As it can be run beyond 24 hours unmanned,
we are now re-pricing work based on a 24 hour day as opposed to a 10 hour day. This high volume capacity and reduced cost per component is already generating interest from customers. “Following on from the reduced cost element, the Delta is a sliding head centre that
can be used with or without a guide bush. This innovation from Tornos was a major factor in our purchasing decision as it drastically reduces the size of bar remnants that are commonplace with sliding head machines. With the increasing cost of material, the Delta machine has a clear advantage
over competitors. One example is a recent job produced from expensive brass bar – the Delta saved 9m of material that would have been binned as remnants if the job was machined on our alternate 32mm sliding heads.”
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