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High Precision CNC Turned Parts Specialist Sub-Contractor Based in Dorset UK using CNC Sliding Head Technology.

High Precision CNC Turned Parts Specialist Based in Dorset UK using CNC sliding head Technology

  • MJB Achieves AS9100 Certification July 2013

MJB Precision Engineering is proud to announce that following Stage 2 assessment, carried out in July by BSI with no non-conformities, its achievement of certification to confirm that its management systems comply with AS9100 Rev C standard at its location in Sturminster Newton, Dorset.
 
        FS 599403
 
Over the prior months, the Quality Management System was refined and improved to include all functional areas in transition from ISO9001 to AS9100 standards.  The ultimate achievement of this goal was made possible through the participation of all employees at every level of the organization.  MJB has a history of attention to quality and it is a natural progression to align our processes and procedures with the quality standards of the industries in which we operate.
 
Our updated AS9100 Rev C and ISO9001:2008 Certificate FS 599403 is now available to view. Please go to the ‘Quality’ section of this website to download a copy.

 
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  • New Machine installed April 2013
 
New Machine installation - Mazak Hyper Quadrex 150MSY - MJB Precision Engineering LtdMazak Hyper Quadrex 150MSY - New Generation 2-Turret / 2-Spindle CNC Turning Center with TWICE THE PRODUCTIVITY Designed for a wide range of machining, with bar capacity Ø65 mm, two turrets and two spindles, Hyper Quadrex 150MSY offers simultaneous cutting of two workpieces to double your productivity.The Hyper Quadrex series is designed for a wide variety of applications – from chuck workpieces to large diameter bar work.Thanks to the conventionally programmed MAZATROL MATRIX CNC, machining programs using both main and second spindles and upper and lower turrets are quickly and easily made. Additionally, unmanned operation system for extended periods of time can be realised by using the machine with the bar feeder system and work unloader for bar workpieces and multi-joint robot for chuck workpieces.

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  • New Machine installed March 2013

Star SR32JN CNC Sliding Head Lathe - New Machine Installation at MJB Precision Engineering LtdStar SR-32 JN CNC Sliding Head Lathe - The SR 32 JN sliding head lathe is equipped with the same tooling system as the SR-32J but without the need for a guide bush. This helps reduce costs by minimising the remnant length and also by not needing a carbide lined guide bush, as is required by typical sliding head lathes.The machine has a 6 station platen together with 4 front working drilling stations and 5 cross driven tools as standard. Front off centre drilling and angular drill attachments are also available for this machine.The weight, robust construction and reliability of the SR-32JN provide excellent machining ability and, together with the safety features built into the Star range of machines, help facilitate unmanned production.

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  • Iscar HP Jetline Tool Technology

ISCAR JETHP tools are designed to operate at extreme pressure and high cutting rates. They deliver a higher performance level than their conventional internal coolant counterparts made for lower pressure service. This additional benefit is provided when using the JETHP line also with conventional machine pressure.ISCAR JETHP line, the innovative solution for ISCAR’s unique tool families, makes the most of your investment in the High Pressure Coolant (HPC) feature.

Now with the availability of high speed machines which offer standard or optional 70-bar coolant systems and through-spindle delivery, HPC technology has grown much more accessible – and proven to be timely. To complete the circle, ISCAR has provided hundreds of special HPC turning tools for a multitude of applications. ISCAR’s solutions have been implemented by satisfied customers for over seven years now.

HPC has proven itself in hundreds of dedicated turning applications on difficult-to-machine materials such as titanium and inconel, at removal rates of up to three times more than that of the conventional flood coolant system. Users report elimination of chip jamming, faster cutting and much longer edge life in outer and inner diameter turning as well as grooving, parting and hole making. The advantage of ISCAR’s JETHP line is also noticeable when machining steel parts, where the chips are more manageable and insert life is significantly improved.

The coolant is delivered with enough force and fast enough to reach the cutting zone as a liquid, not a vapor. In the liquid phase, it lubricates the cutting process, as it quenches the molten chip, shattering it into smaller, more manageable pieces. Also, because of its internal flow path, HPC keeps the tool, insert and workpiece cooler, leading to much longer tool and equipment life.

Another benefit is that delivering coolant close to the shear zone improves machineability of the material under high speed conditions. Higher pressure coolant, directed right at the cutting zone, creates smaller chips, whether the material is titanium, inconel or steel.

ISCAR JETHP tools are designed to operate at extreme pressure and high cutting rates. They deliver a higher performance level than their conventional internal coolant counterparts made for lower pressure service. This additional benefit is provided when using the JETHP line also with conventional machine pressure.

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Lubriserv XS9 Fully synthetic extreme performance cutting fluid  formulated using  advanced synthetic ester technology instead of conventional mineral oil. Cutting trials under way using fully synthetic extreme performance cutting fluid  formulated using  advanced synthetic ester technology instead of conventional mineral oil. This technology achieves  extremely high cutting performance, ideal for use in Sliding Head Lathes like Star, Citizen, Dugard and Tornos machines.LUBRICUT XS9 is clean, water clear and designed to improve the working environment by reducing oil mist formation, keeping machines and components clean and with its high flashpoint properties it significantly reduces any fire risk. It doesn’t stop there either – as LUBRICUT XS9 is a much lower viscosity than most neat cutting oils the dragout consumption on your swarf can be up to 60% lower. Results so far are looking good................

Will we never machine with mineral oil again ?

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  • New Investment of Surtronic ® R-100 series High speed roundness measurement system

Surtronic ® R-100 series High speed roundness measurement system - MJB Precision Engineering Ltdfor the bearings industry A range of roundness products robust enough for the shop floor but accurate enough for any inspection room. Working closely with bearings manufacturers, Taylor Hobson has focussed on the key attributes that are most important for quality control in today’s precision ndustries.  The new Surtronic R-100® series instruments offer a flexible solution for all your roundness and form requirements with a variety of systems and application specific accessories along with fixtures that can be tailored to your specific need.

A range of roundness products robust enough for shop floor but accurate enough for any inspection room.Working closely with manufacturers across a wide range of industries including precision bearings, automotive and aerospace engineering Taylor Hobson have focused on the key attributes that are most important for quality control in today’s precision industriesThe new Surtronic R100/R105 of instruments offer a flexible solution for all your roundness and form requirements with a variety of systems and application specific accessories and fixtures that can be tailored to your specific need. 

World’s highest throughput roundness system…• Increase manufacturing output • Ensure part traceability• Reduce part scrappage • Improve ‘right first time’

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  • Werma Win Complete Machine Data Collection system (MDC system) Installed 7.03.2013

Werma Win Complete Machine Data Collection system (MDC system) Installed MJB Precision Engineering has recently invested in A Werma Win Complete Machine Data Collection system (MDC system) to reduce machine down times to a minimum, avoiding production losses and thus increasing the productivity of manufacturing operations. 

  • Economical wireless-based Machine Data Collection system (MDC system)
  • Analyse and optimise production processes
  • Machine status and part count monitoring of a wide range of different machines

WERMA wireless solution was installed by Celtic Services Ltd

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  • Subcontractor reveals the merits of buying a CNC multi-spindle auto


Founded in 1994 by Mark Bevan, MJB Precision Engineering relocated ten years later to its current premises at Sturminster Newton. It allowed the subcontractor to offer a modern manufacturing facility for prototyping and short batch work through to mass production of mill-turned parts. In October 2011, the 15-employee company took its business to the next level by investing in a 22 mm capacity Index CNC multi-spindle automatic from Geo Kingsbury Machine Tools.


The Index MS22C multi-spindle auto installed at the Sturminster Newton factory of MJB Precision.Until the German-built MS22C six-spindle auto arrived, the subcontractor relied on sliding-headstock lathes to produce components of 20 mm diameter and below, while single-spindle fixed-head lathes were deployed for diameters up to 300 mm.


The company focusses on providing support to manufacturers in the UK and beyond, co-operating closely on R&D with customers in the bearing, aerospace, medical and defence industries in particular. Components are routinely machined from plastics, carbon and stainless steels, tool steels, aluminium, copper-based alloys, titanium and exotic alloys.


It was winning a large automotive contract that prompted Mark Bevan to analyse the best way of producing four different tool steel parts in batches of 3,000 per week each, which are assembled into a new product for luxury passenger cars. He had to take into account that quantities are set to rise steeply in 2012.


Mark Bevan checking a setup on the MS22C.At the outset, Mr Bevan began machining the components on three sliding-head lathes, 20 hours a day plus lights-out running, six days a week. However, five more sliders would have been needed to cope with predicted demand. There was insufficient space in the factory to house that number of extra machines, together with their full-length bar magazines, so relocation to larger premises would have been necessary.


Furthermore, the extra staff needed to operate another five lathes would have raised overheads and consequently increased unit production costs, which are notoriously sensitive in the automotive industry.


The space and labour cost issues were resolved at a stroke by deciding to install an Index CNC multi, which can mill-turn in a 24-second cycle a component that takes a sliding-head lathe 120 seconds to complete, representing a five-fold productivity increase. Capital investment in the multi was equivalent to buying five sliders; and being a single machine, the multi fits neatly into the available space in MJB's factory.


A scara robot on the MS22C performs operations on the reverse of a parted-off component in conjunction with separate rear-working tools.The family of four automotive parts are in the process of being transferred to the MS22C, which has a scara backworking unit with synchronous pick-up spindle for presenting each parted-off component to dedicated backworking tools. PPAP (production part approval process) has already been carried out on the first component, with the other three approvals to be completed in early 2012.


Mr Bevan commented, "Apart from keeping down overheads and occupying a small footprint, the Index multi has delivered other advantages as well.


"We find that the machine is more rigidly built than our single-spindle lathes, so vibration is minimised, leading to much better tool life. We typically machine 400 components on one of our sliders before a tip needs changing, whereas the number rises to 1,000-off on the Index.


"Higher feeds and speeds can be used and there is no need to compromise the parameters at any of the spindles, as all are individually adjustable, unlike on old cam-type multi's.


"So productivity and quality are maintained and the process is more predictable, allowing us easily to hold the required 1.67 Cpk on the parts and fulfil our customer's kanban delivery requirements next year.


"The output of the single Index multi is high enough for it to cope with producing the required volumes of all four automotive components for the foreseeable future.


"He added that a further benefit of using the MS22C derives from it being a fixed-head lathe, albeit with six C-axis spindles. It means that bar remnants are around five times shorter than the 300 mm of tool steel left after machining the last part on a sliding-head machine, which equates to around £10 in material saved on each bar.


The flexibility of having CNC on a multi has dramatically reduced economic batch size to between 5,000- and 10,000-off, giving the machine much more scope than before for taking work from single-spindle machines. Changeover is faster than on a cam multi and can be as short as one hour if the same collets and most of the same tooling are used for producing the next part. Naturally, the expense of machining or purchasing cams is avoided.


Further versatility is afforded by having two tool slides serving each spindle. Both slides are capable of performing internal or external turning, or boring, or driven tool work, so the user is not restricted to designating one type of tool in any position, helping to optimise flexibility and reduce machining times. Standard equipment on MS-series machines includes high-pressure, through-tool coolant and filtration to extract all particles of metal larger than 20 microns, which improves tool life. Coolant temperature is constantly controlled, ensuring continuous, high accuracy machining.


Source: http://www.gkholdings.com/news-gkh-1231.html


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