Available as a standard, very cost-effective ready-to-run package, a 7-axis turn/mill chucking cell has an integrated programmable automatic loading and unloading system.

Available as a standard, very cost-effective ready-to-run package, the 7-axis Colchester Tornado T6MS turn/mill chucking cell with a fully integrated programmable APL 5000 automatic loading and unloading system will be demonstrated on stand 5334 at MACH 2006. Available through Colchestersales (UK) of Heckmondwike, UK, the Tornado T6MS with APL 5000 is a true fully integrated cell that is able to combine first and subsequent turning and milling cycles in a 'lights-out' environment with its part handling automation able to 'handshake' with customer supplied conveyors, pallet stockers and carousel type units. Most important with this new Colchester chucking lathe development is that the system is self-contained within the machine guarding and does not require additional fencing and safety areas normally mandatory for robotic based systems.

The cell has been devised for maximum spindle uptime and machine utilisation with the main and subspindle of the Tornado T6MS able to exchange the component using 'kissing' spindle techniques to enable first and second operations to be combined into a single cycle.

Here the APL 5000 feeds the work to the main spindle of the machine and retrieves the completed part from the subspindle and will only add between six and eight seconds to the normal production cycle.

This is a far more cost-effective solution to achieve a consistent cycle that could ever be matched by an operator, especially with forgings, castings or billets up to 80mm diameter by 100mm long and weighing up to 5kg.

The automation is fully programmable via teach pendant and operates through the Fanuc 18i-TB control with Manual Guide i software on the machine as standard while being integrated with Colchester Lathe developed automation programs.

The machine concept involves a loading beam mounted above and onto the headstock and running parallel to the centre line or Z-axis to link component storage at the headstock side of the machine to the cutting zone.

Powered via ballscrew and servo drives, a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems Whatever type of material or work handling system is connected, the machine is able to manipulate raw material supply to the main spindle and accept the off-load of completed parts from the main or subspindle enabling the production cycle to continue independent of the loading system.

The loading system therefore is able to carry on to complete the handling sequence with the part storage elements and is able to be parked clear of the machine working area to enable normal machine operation.

The Tornado T6MS has a 440mm swing over bed and 220mm maximum turned diameter by 450mm long with a 54mm bar capacity and options of 170mm or 210mm chuck size.

The subspindle chuck size is 130mm.

The 15kW, 6,000 rev/min main and 5.5kW, 6,000 rev/min subspindle are serviced by a 12 station all-driven tool turret with 3.7kW, 5,000 rev/min drive.

Rapid traverse rates are 30m/min in Z and 25m/min in X.

The machine can be fitted with Renishaw probing for in-cycle qualification with feed-back correction to the control and torque-based tool monitoring; sister tool replenishment is also available.

Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that provides some 300% improvement in stability over conventional cast iron.

This system uses an encapsulated polymer concrete base fill to which is mounted a compact cast iron bed that will minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.

* Colchester Lathe Company at MACH 2006, NEC, Birmingham, UK, May 15-19, Hall 5, Stand 5334.