Machine tools manufacturer Starrag has been selected by US engineering firm Metalex Manufacturing to supply a large-capacity, multi-axis Droop+Rein portal-type machining centre for its new Center for Advanced Large Manufacturing.
The machine – the largest ever installed by the contract manufacturer – represents a significant investment by Cincinnati-based Metalex.
The machining centre will provide the firm with the ultimate in flexible production capacity to meet all foreseeable demands in terms of producing highly-accurate milled and turned workpieces in a single set-up.
The portal type milling and turning machine – which is being especially configured to meet Metalex’s current and future needs – offers an expansive 19 metres in the X axis and 9 metres in Y. The 7 metres vertical clearance is covered by the 3 metres of ram stroke (Z axis) and a continuously moveable crossrail of 5.5 metres (W axis). The C axis integrated in the ram with infinite rotation and the +/- 95 degrees swiveling B axis of the universal fork-type milling head complete the six axes.
All heads will be designed, built and tested by Droop+Rein in Bielefeld. Furthermore, the machine will be prepared for more heads to be fitted in the future as new jobs arrive. The versatile 400-pocket robot tool magazine ensures automatic loading of three different tooling systems into the selected milling and turning heads.
Indeed, the six-axis Droop+Rein T Series machine is projected to not only satisfy existing projects but its machining envelope of up to 19 metres table length, 9.5 metres between the columns and 7 metres under the spindle will likely also attract new work.
Metalex’s desire to source a machine that would not only satisfy current production needs but also meet all projected demands in the years ahead saw it make contact with a number of machine builders, including Starrag which in the past has supplied it with a number of machines (a Dörries vertical turning lathe and two Starrag STC horizontal five-axis machining centres).
Droop+Rein Product Sales Manager, Heiko Quack said: “We sat down with Metalex to discuss what was needed - in short, a very flexible, large-capacity and high-accuracy machine with multi-axis capability that would efficiently accommodate a variety of parts in a range of materials and produced to tight tolerances.
“Applying our proven ‘Engineering precisely what you value’ philosophy, our relationship with Metalex evolved into looking at various solutions and machine types available under the Starrag portfolio and together we arrived at the Droop+Rein T Series - a portal milling machine that offers superb rigidity, essential for highly-accurate machining. We added the two rotary tables and the turning tool holders for in-cycle turning operations and expanded the horizontal and vertical clearances to suit.”
Mr Quack confirms: “With no comparative workpieces, from the outset we knew that Metalex wanted a machine that would meet all eventualities and, as always in such cases, Starrag applied the best world-class technology solutions including Balluff tool identification, Renishaw probing, BLUM laser tool measuring, video monitoring of the work area using four cameras, ARTIS tool and process monitoring and Brankamp collision monitoring - all integrated via the machine’s Siemens 840 D SL CNC system.”
The machine is due for delivery in 2020 and production is scheduled to commence in 2021.
Kevin Kummerle, CEO of Metalex, summarised the pre-order project phase, saying: “For Metalex to continuously evolve and be a company of the future, a combination of our capabilities, technology and people must work together to create innovation that sets us apart from others. Our customers need to know that their key suppliers are committed to be at the leading edge of their industry offering the best total value in terms of quality, technology, cost and service for today and for the long run.
“Metalex applied these same considerations in our evaluation process, looking for a partner that could provide a complete technology solution for our application; a highly flexible and accurate machine configuration integrated with the latest in technology supported by a service organisation capable of rapidly solving challenges that arise. All of these factors are why Metalex selected Starrag as our partner on this critical project.”