Aerospace sub-contractor's machining centre has the ability, which allows the set-up and proving of jobs on the second pallet during the day, making it possible to run a successful night shift.

Victoria Production Engineering, part of the Hyde Group, needs high quality, reliable machining centres to satisfy its many and varied customers. The Manchester based company produces components mainly for the aerospace sector coupled with parts for the valve, petro-chemical, and mining industries. Approximately 70% of its work is Aerospace, which it wins through competitive tender with the backing of the Hyde Group, which itself comprises 36 companies spread across the North West of England.

Hitachi Seiki machines had already proved their reliability within Victoria Production Engineering, so as machines needed replacement and capacity requirements grew, the natural choice was Mori Seiki (Mori Seiki acquired Hitachi Seiki).

Rob Randle, sales director for Victoria Production Engineering, explained, 'The first Mori Seiki NV5000 we purchased was to replace a 20 year old Wadkin.

We had been very satisfied with the service and reliability of the Hitachi Seiki machines, and we felt we could not afford to buy a machine which might break down.' The NV5000 is fitted with a 4th axis and a pallet changer, and is set up to run between 30 and 40 different repeat jobs in batch sizes of 10 to 50.

The ability to set and prove jobs on the second pallet during the day makes it possible to run a successful night shift.

Additionally, the new machine can run at 12,000 rev/min and contains in cycle probing, as well as a tool setter which checks for tool wear and manages tool life.

Randle continued, 'The Mori Seiki NV5000 has enabled an increase in capacity towards our planned growth targets.' Within a twelve month period, the first Mori Seiki was followed by a NH4000DCG and a second NV5000.

The NH4000 DCG was installed to meet additional capacity requirements for components which fit within its 0.5m3 operating envelope.

Randle said, 'This machine is compact yet big enough for our parts, and it is fitted with a 120 station automatic tool changer.

The capacity of the ATC has made it possible to manufacture the parts scheduled for the machine without switching tools.

Once programmes are loaded via our DNC link, production can start immediately.' The high precision parts manufactured by the company frequently require tolerances of 0.0013mm and surface finishes of 16 micron (probably Ra - Ed).

During the design of the machine, Mori Seiki used dynamic analysis of cutting forces and high quality Japanese manufactured castings to optimise the rigidity of the NH4000DCG, while the Driven at the Centre of Gravity technology contributed to its low vibration levels.

Randle added, 'We can use higher revs and faster feed rates without compromising on quality or repeatability.' A five year contract for the supply of titanium and aluminium brackets for the aerospace industry prompted investment in the second NV5000 with a 4th axis.

As part of the service contract, Mori Seiki engineers spent time on site helping to optimise the tooling, programming, and fixturing for the brackets, with the aim of minimising both the setup and cycle times for the twelve variations.

Rob Randle emphasised the importance of reliability, 'We can not afford to have a machine down as this will affect the schedule requirements of our customers.

Mori Seiki's delivery, installation, and backup are superb.

Any additional technical information we require is supplied straight away.' Having three very similar machines running 100h/week each has helped productivity through the compatibility of the CNC programs, the setup, and the operation - this has increased operator flexibility and cut setting times.

Should we have any extra capacity on the second NV5000, we can easily transfer jobs to fill it.' With increasing material prices and the rising cost of the treatments required on some jobs, savings at the machining stage are very important.

Randle concluded, 'The customer wants cost reductions, which means we have to be both smarter and quicker.

The productivity gains we have achieved with our Mori Seiki machines will help with our ongoing cost reduction programme.' * About Mori Seiki (UK) - Mori Seiki UK, the UK arm of Mori Seiki Co, services and supports Mori Seiki and Hitachi Seiki machines in the UK market.

Mori Seiki is one of the world's leading manufacturers of metal cutting machines.

With its head office in Nagoya Japan, it employs 3,300 people, and is committed to innovation, quality, and service, with a range of machines to cover all industry sectors.