https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/09/17140415/The-Kitamura-Mycenter-HX500iG-at-ELE-640x360.jpg
    Machining

    Dugard turbocharges output with Kitamura install

    • By Dugard
    • September 17, 2020
    • 4 minute read

    ELE Advanced Technologies Ltd is a company with an aerospace pedigree that dates back to 1955 when Earby Light Engineers (ELE) was founded to manufacture compressor blades for Rolls-Royce. In the 65 years since, the Colne company has expanded its scope by targeting the aerospace and automotive sectors.

    In fact, the diversification into the automotive commercial diesel market has seen the company open a manufacturing facility in Slovakia to supply global commercial diesel engine manufacturers. In the last decade, ELE has invested heavily in production equipment for the manufacture of IGT, aerospace and automotive power generation components and assemblies such as blades, vanes and a range of turbine components. Part of this investment has included the installation of three Kitamura machining centres, with the latest machine arriving from Dugard at the start of April – during the pandemic lockdown period.

    The Kitamura Mycenter HX500iG/630 from Dugard Machine Tools is an identical model and specification to an HX500iG/630 installed in 2017. Commenting on the purchase of the third Kitamura, David Dudley from ELE Advanced Technologies says: “The reason that we bought the third machine is that the process from the other two machines is such a repeatable process, we wanted a machine that we could plug in and play, and just start making components that will conform to specification perfectly.”

    Alluding to the Mycenter HX500iG/630 machine, David continues: “The parts we are making on the Kitamura machines are being installed on an industrial gas turbine engine and they are manufactured from exotic materials like nimonic. The parts have very tight tolerances and the materials are very difficult to machine. With the Kitamura machines, you can load a part, machine it and then be confident that when you put it on the CMM, everything will be 100% correct.”

    Extending upon this point and referring to the long cycle times required with the parts, David says: “The beauty of the Mycenter is that we can now use ceramic endmills from NTK and these allow us to remove material a lot faster than before. This gives us the ability to rough machine a lot faster and then come in with finishing tools for the final passes.”

    Taking this productivity a step further, the Kitamura Mycenter HX500iG/630 machines have a 50 tool ATC as standard, along with a high-torque 12,000rpm dual contact BT50 spindle configuration and a twin pallet configuration. Discussing this, David says: “The reason for the twin pallet setup is twofold. Firstly, there is the obvious benefit that we can load one pallet whilst the other is ‘in-cycle’ which reduces our setup times and keeps the spindles turning. Additionally, we are introducing a lot of new products all the time. With the twin pallet, we can use one pallet for production parts whilst simultaneously using the next pallet for development parts. This ensures we can get new projects up and running without disrupting production. This allows us to mix-and-match our production.” Furthermore, the Kitamura incorporates a 500 by 500mm pallet with the facility for a 630mm pallet, if needed. Machining all faces with sufficient clearance is not an issue as the machines have an X, Y and Z-axis travel of 870 by 800 by 930mm.

    Both Dugard and Kitamura actively promote the geometric precision of the machines and the hand-crafted manual scraping that makes the Mycenter range so precise. Commenting on this, David says: “The three Kitamura machines are heavy-duty machines and we know we can load both pallets on the machines and be confident that the parts coming off the machine are right first time. From a productivity perspective, we run the machines at 12,000rpm with 60m/min rapids. Both the Kitamura HX500iG machines in this cell are identical. They have the same spindles, tooling carousels and configurations.”

    Looking at the machining strategy and potential for deflection when machining turbine components, David says: “This was something we clearly had to consider when we were buying these machines, but the robustness of the Kitamura range means that deflection is not a factor.”

    Concluding on the service, David summarises: “The service has been fantastic. We bought the machine at the end of 2019 and the delivery was scheduled during the height of the pandemic. We are in the north of England and Dugard are in Brighton, but they delivered the machine and got it running in a matter of weeks, an excellent effort.”

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/09/17140415/The-Kitamura-Mycenter-HX500iG-at-ELE-640x360.jpg

    Dugard turbocharges output with Kitamura install

    ELE Advanced Technologies Ltd is a company with an aerospace pedigree that dates back to 1955 when Earby Light Engineers (ELE) was founded to manufacture compressor blades for Rolls-Royce. In the 65 years since, the Colne company has expanded its scope by targeting the aerospace and automotive sectors.

    In fact, the diversification into the automotive commercial diesel market has seen the company open a manufacturing facility in Slovakia to supply global commercial diesel engine manufacturers. In the last decade, ELE has invested heavily in production equipment for the manufacture of IGT, aerospace and automotive power generation components and assemblies such as blades, vanes and a range of turbine components. Part of this investment has included the installation of three Kitamura machining centres, with the latest machine arriving from Dugard at the start of April – during the pandemic lockdown period.

    The Kitamura Mycenter HX500iG/630 from Dugard Machine Tools is an identical model and specification to an HX500iG/630 installed in 2017. Commenting on the purchase of the third Kitamura, David Dudley from ELE Advanced Technologies says: “The reason that we bought the third machine is that the process from the other two machines is such a repeatable process, we wanted a machine that we could plug in and play, and just start making components that will conform to specification perfectly.”

    Alluding to the Mycenter HX500iG/630 machine, David continues: “The parts we are making on the Kitamura machines are being installed on an industrial gas turbine engine and they are manufactured from exotic materials like nimonic. The parts have very tight tolerances and the materials are very difficult to machine. With the Kitamura machines, you can load a part, machine it and then be confident that when you put it on the CMM, everything will be 100% correct.”

    Extending upon this point and referring to the long cycle times required with the parts, David says: “The beauty of the Mycenter is that we can now use ceramic endmills from NTK and these allow us to remove material a lot faster than before. This gives us the ability to rough machine a lot faster and then come in with finishing tools for the final passes.”

    Taking this productivity a step further, the Kitamura Mycenter HX500iG/630 machines have a 50 tool ATC as standard, along with a high-torque 12,000rpm dual contact BT50 spindle configuration and a twin pallet configuration. Discussing this, David says: “The reason for the twin pallet setup is twofold. Firstly, there is the obvious benefit that we can load one pallet whilst the other is ‘in-cycle’ which reduces our setup times and keeps the spindles turning. Additionally, we are introducing a lot of new products all the time. With the twin pallet, we can use one pallet for production parts whilst simultaneously using the next pallet for development parts. This ensures we can get new projects up and running without disrupting production. This allows us to mix-and-match our production.” Furthermore, the Kitamura incorporates a 500 by 500mm pallet with the facility for a 630mm pallet, if needed. Machining all faces with sufficient clearance is not an issue as the machines have an X, Y and Z-axis travel of 870 by 800 by 930mm.

    Both Dugard and Kitamura actively promote the geometric precision of the machines and the hand-crafted manual scraping that makes the Mycenter range so precise. Commenting on this, David says: “The three Kitamura machines are heavy-duty machines and we know we can load both pallets on the machines and be confident that the parts coming off the machine are right first time. From a productivity perspective, we run the machines at 12,000rpm with 60m/min rapids. Both the Kitamura HX500iG machines in this cell are identical. They have the same spindles, tooling carousels and configurations.”

    Looking at the machining strategy and potential for deflection when machining turbine components, David says: “This was something we clearly had to consider when we were buying these machines, but the robustness of the Kitamura range means that deflection is not a factor.”

    Concluding on the service, David summarises: “The service has been fantastic. We bought the machine at the end of 2019 and the delivery was scheduled during the height of the pandemic. We are in the north of England and Dugard are in Brighton, but they delivered the machine and got it running in a matter of weeks, an excellent effort.”