Fanuc Software Installation Manual

[Luz Tonks]

Thefirst UK installation of the latest high-speed Fanuc F-series VMC with24,000revs/min spindle, 54m/min rapid traverse rates and 1.6 sees chip-to-chiptoolchange has gone directly into production of Airbus and Boeing aerospacecomponents at Protocon Engineering. The T21/F machine joins three existing Fanucmachining centres and a Fanuc wire EDM also supplied by 600 Centre of Shepshednear Loughborough that will significantly help to satisfy a rapidly rising orderbook at the 18 employee Southend-on-Sea (Essex) specialist sub-contractmachinist.

Experiences of high reliability, a fast cycling ability and a means ofproviding consistent quality were the motivators for Matthew Smith and father,Managing Director Geoff Smith, to install the latest Fanuc VMC based on theirin-depth experiences over 15 years with the Fanuc machine range.

Protocon Engineering began life in 1964 as a prototype machinist underMatthew's grandfather using manual equipment. It moved into pre- production workthen eventually offered a full production turning, milling and drilling servicewith a very early Fanuc Drill Mate from 600 Group.

The Drill Mate's reputation of being a workhorse led Protocon to install aFanuc Robodrill T10A through 600 Centre, which was eventually traded-in for amuch improved performance Fanuc T14/B VMC. Over the last few years, two furtherFanuc T21/D VMCs have been installed alongside the T14 to create a bank ofmachining centres characterised by quick cycling as well as common setting,tooling, programming and operation. It is this machine portfolio that the FanucT21/F has joined.

Indeed, such is the relationship with 600 Centre and the Fanuc product thata Fanuc Alpha O wire EDM was installed some seven years ago this, too, has givensterling service and is largely used in unmanned mode for toolmaking, prototypeand production machining.

This prototype-to-production capability has also led the business into themedical sector for components used in drug testing devices, computerised medicaltrolleys, fibroscopes and endoscopes as well as parts for the MoD and motorsportthus reducing risk and total dependence on one sector.

With such a background, a wide spread of ferrous and non-ferrous materialsincluding aluminium, various alloys and stainless steels. Titanium, brass,copper, nylon, phosphor bronze, nickel iron and nickel silver as well as theoccasional difficult to machine Inconel are machined in batches that range from50 to a more consistent supply run of over 1,100 parts a week through the Fanucmachines.

The latest Fanuc T21/F, launched in Europe during September at the EMO 2007exhibition in Hannover, has a working volume of 500m/min in X by 300mmin Y and 330mm in Z and incorporates thermal displacementcompensation in each axis to provide the advantage of an enhanced repeatabilityand accuracy over long periods of production. The high speed 24,000revs/minspindle provides Protocon with the capability to increase feed rates above theD-series machines and effectively use small milling cutters and drills toadvantage on the typical fine detail demanded by many of the parts produced.

The ability to switch programs and tooling between the VMCs is important toProtocon because it leaves the GibbsCAM offline programming system to be used onnew work in support of the Fanucs and other CMC lathes in use.

However, the Fanuc wire EDM is always programmed at the control due to theease of the system in its role in producing an aerospace component such as astainless steel fuel pump impeller, with up to eight vanes that are wired fromsolid. The multiple part fixture is loaded with 10 pre-turned blanks and themachine, that has just been rejuvenated by a 10,000 upgrade by 600Centre, is set to run in the late afternoon with the parts completed overnightready for unloading the following morning. Each of the ten parts is secured inthe fixture by a central Alien screw, and eight screws to retain each segment asit is cut from the blank.

One particular component for a Boeing fuel system is initially turned thenmilled on the Fanuc T21/D to produce two cut out sections and a slot in the wallof the cylindrical part from which a highly accurate internal cam form is wirecut. Once again, autocycling of both the VMC and wire EDM leads to verycost-effective production and ensures the precision demands of this criticalcomponent are maintained.

Currently, they are run through 11h days over a six day week but with thecontinued influx of work, another shift could be instigated to give totalaround- the-clock production while requiring limited supervisory attendance.

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