Continuous improvement programme is the catalyst for investment in advanced, multi-axis machine tools.

Hertfordshire-based precision manufacturer - Drurys Engineering Ltd has recently invested in 2 new, advanced machine tools from Hardinge Machine Tools, Leicester.

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The machines – a Bridgeport XR 300 5AX (Super-Precision 5-axis machining centre), and a Hardinge RS 51MSY (multi-tasking turning centre with sub-spindle and driven tooling), provide tangible evidence of a ‘company-wide’ continuous improvement programme implemented by Drurys designed to increase organisational productivity, performance and competitiveness.

The new machines are being used by Drurys to manufacture high-precision complex parts (and mould tools) for customers operating in the aerospace, defence, F1/motor sport, oil/gas and pharmaceutical sectors etc.

Components manufactured by Drurys on the new machines are characterised by their accuracy (10 micron tolerance or better), and high surface finish (Ra 0.8um).

Parts are typically manufactured in small batches (which includes prototypes and one-offs – through to 50/100 off in some instances), and materials used to manufacture parts are diverse – aluminium, inconel, titanium, Stainless, exotic alloys etc.

Responding to customer demands

The decision to invest in multi-axis/multi-tasking machine tools from Hardinge is explained by Drurys’ managing director Richard Dunn:

‘We have positioned Drurys as a market-leading, premier precision subcontractor – and the long-term partnerships we have developed with a number of blue-chip OEM and Tier 1 manufacturers are evidence of our success.

‘The key to maintaining and strengthening these relationships is entirely dependent on our ability to continually (and consistently) meet our customers’ changing manufacturing requirements…and an essential element in helping us respond quickly and positively to these changes is the machine tools we have at our disposal.

‘The sectors where we operate and the customers we work for mean that guaranteed part accuracies, shorter lead times and cost competitiveness are always high on the agenda.

‘These are the critical success factors that influenced our decision to invest in multi-axis machine tools, and why we chose Hardinge as the machine tool manufacturer to supply them.’

XR 300 5AX: Bridgeport 5-axis milling machine

The Bridgeport XR 300 5AX machine provides Drurys with 5-axis positional (3 + 2) and full simultaneous 5-axis machining capability. The machine’s rigid build and construction minimises vibration, and also helps reduce thermal distortion – both essential to maintain workpiece accuracy and maintain/extend tool life.

The machine is compact (so floor space is not an issue), and is equipped with a powerful 25kW 12,000rpm spindle that is capable of delivering high material removal rates and super-fine surface finishes.

A 48-position ATC ensures that the machine can be set-up and left to run unattended and integrated Renishaw probing systems (that allow in-process measurement) optimises the machine’s reliability.

RS 51MSY: Hardinge multi-axis turning centre

The Hardinge ultra-productive, collet-ready RS 51MSY (51mm bar capacity) turning centre invested in by Drurys is equipped with live tooling, Y-axis, sub-spindle and full C-axis capability on both spindles.

The machine’s live tooling capabilities allows Drurys to perform cross- or end-milling/drilling operations, and the Y-axis function means that thread milling and complex off-centre milling and drilling operations on either the main or sub-spindle can be achieved.

The machine, like the XR 300 5-AX, allows Drurys to machine jobs in fewer set-ups (in many cases just one set-up), thereby helping the company to reduce lead times, improve part accuracies (due to less workhandling), and avoid production bottlenecks.

Says Richard Dunn:

‘The new machines from Hardinge have had a dramatic effect on our performance. We’re more flexible, more productive and are able to respond much more effectively (and quickly) to our customers’ demands and requirements.’

Not just machining performance

Drurys’ decision to invest in Hardinge technology was not just about the machines.

Continues Richard Dunn:

“Machine tool reliability, and the service and applications support available from Hardinge were also key considerations.

The customer deadlines we face means that machine tool downtime is not an option for us – so it was important (if not critical) that the machine tool supplier we selected to provide the new technology took this on board.

We have worked with Hardinge for a number of years and appreciate their quick response whenever we have had machine tool performance issues in the past…and we also value their first-class applications and technical help and support too.”

What next?

Drurys’ investment in multi-axis machine tools is part of the Company’s continuous improvement programme.

With the 2 new machines working to full capacity Drurys has now invested in a third 5-axis super precision machine – a large capacity XR600 5 AX.  This latest investment not only relieves the pressure on existing machine tools and manufacturing processes - but also increases the size of parts/components that now can be 5-axis machined by Drurys.

Other areas within the company are being improved with the introduction of a new MRP (Manufacturing Resource Planning) System in recent months, and will also be re-vamping its already impressive Inspection facility to keep pace with the increased technology being used for manufacturing.