BROADCASTS.com

Diecaster Introduces Automation.

After long using robotic systems in its aluminium diecasting foundry, Andover-based MRT Castings has started to apply automation in its machine shop.

This follows the arrival of a Brother Speedio M140X2 5-axis mill-turn cell.

Fed with raw material from an interlinked Feedio robotic handling system from the same manufacturer, it is the first to be installed in the UK.
The turnkey cell was supplied by Whitehouse Machine Tools to keep production costs down and remain competitive.

A user of Brother 30-taper, 4-axis machining centres since the early 1990s, the company now operates twenty machines, half of which are equipped with a pallet changer.
MRT’s Managing Director Phil Rawnson says: “Our pursuit of single set-up production means that we sometimes find ourselves processing parts on our lathes that entail only one-third turning, with the remainder of the cycle taken up by prismatic machining using live tools in the turret.

It's an inefficient method of milling and drilling, as the rotational speed and power of the limited number of tools in a lathe are considerably lower than those of the spindle on a machining centre, which also has the benefit of access to more tools.

So, we decided to invest in a mill-turn machine and identified the Brother M140X2 as ideal for our needs.”
“When not performing turning, the C-axis table and A-axis trunnion can position a component in the two rotary axes for 3+2 prismatic machining, which is needed for most components.”

To leverage the high productivity potential of the M140X2, the plan is for any rotational part that requires a majority of milling and drilling in its cutting cycle, whether machined from a casting, billet or bar, to be put onto the 5-axis machine.

The Feedio system equipped with a 6-axis ABB robot is capable of handling billets up to 80mm diameter or aluminium castings up to 120mm diameter.
A vision system and built-in PC allows the robot to detect where on the upper inlet conveyor of the Feedio, the raw material has been placed, so billets do not have to be aligned on a grid or in a tray.

Phil Rawnson say: “Until recently, we operated a day shift with a few hours’ overtime in the early morning and evening.

The new Brother cell has added to this, allowing us to run lights- out for up to eight hours.”
The first contract to be fulfilled in the automated cell is a family of aluminium bodies for a range of LED light fittings.

Prototypes were produced on twin-spindle lathes with live tooling, but as only around 30% of the machining is rotational, it is better suited to production on the M140X2 mill-turn.

Cycle time has been almost halved from 15 to 8 minutes, thanks to the higher power of the 16,000rpm milling spindle.
To assist in finding the best robotic handling configuration to go with the machine, MRT enlisted the help of the Manufacturing Technology Centre in Coventry.

After researching the market, towards the end of 2017 its advisers concluded that a conveyor system and a teach-in programmed, vision-enabled, 6-axis robot with interchangeable 3D-printed grippers would best suit the types of components produced and machines in use at Andover.

Coincidentally, that was just when Brother launched the Feedio system at EMO 2017 in Hannover.
Phil says “Feedio is suitable for retrofitting to all our Brother machining centres, both non-APC and twin-pallet types, allowing us to reduce operator attendance during the day.

Quality is enhanced, as workpiece loading is more consistent. In addition, we are able to extend our single day shift by taking advantage of lights-out running into the evening or even overnight.”
“We see automation as the future.

We plan to target a wide range of different components for production in the new mill-turn cell and will be looking in particular at parts where turning content is less than half of the cycle time.