Linear machines lead to a leap in business

Brian Turner, Managing Director, said: “We invested in our first DMG MORI NH5000 over five years ago when we were located in Slough. Since then we moved to Bracknell, purchasing the premises and doubling in size to 7,500ft². We are planning to double in size again as soon as we can. We have continued to invest in DMG MORI machines because of their reliability. We cannot afford to have downtime due to machine breakdown as we are running 24 hours a day. DMG MORI provides the reliability and service essential for our business.”

As well as machining the aerospace parts, B-Tech Engineering assembles them in a controlled environment – the whole factory is air conditioned. Some of the assemblies are complex and can have up to 90 parts and require skill to achieve the required quality standard with no blemishes on the components, excess adhesive or air bubbles under the laminates.

Working with aerospace customers enables B-Tech Engineering to make parts for stock. Marc Turner, Operations Director said: “Our objective is to keep the machines running all the time, as that is when they are earning money and it is what they are designed to do. Although we may have more stock in finished parts than other companies, we achieve very high levels of machine utilisation and find that this is the most cost effective and efficient way for us to operate.”

Migrating to 5-axis machining with the DMU 60 eVo linear machines is a major step forward for the company, especially for small batch quantities. Marc Turner said: “Setup times have been virtually eliminated with 5-axis machining. We use Lang Makro-Grip vices enabling us to clamp securely on a very small section of the billet, machine the complete part in one or two setups and break out a finished part from the finish machined billet.”

With CELOS on the machines and the PC version in the programming office, B-Tech Engineering can make tooling, setting and CNC data available at the machine, enabling the operator to check and be sure about the next job before machining starts. The company is able to cut 2-3 completely different jobs overnight and, because of the speed and ease of setting, it does not require a skilled person to operate the machine.

Whilst using bull nose cutters, the job can be tipped so that the machine is not cutting with the end of the tool, which can cause ‘pick-up’ and hence marks on the job. Machining with the side of the bull nose produces a superior surface finish, important for the markets served by the company. B-Tech is also able to make use of trochoidal cutting techniques, machining pocket features with the full depth of the heat shrink tools it uses.

Programmed in MasterCAM, the extra capacity delivered by the DMU 60 eVo linear has made it necessary to employ an additional CAM programmer. Marc Turner added: “The DMU 60 eVo linear on order will have 120 tools and the capacity to add ten pallets. We will stick with a DMG MORI pallet changer, when we invest in it, so that we have one trusted service contact for the complete system.  The extra tool stations will enable us to use sister tooling and, adding the pallets, will make it possible to make more parts overnight. We could have purchased a less expensive machine but we need to be moving forward with technology specifying the best machine with all the optional extras.”

B-Tech’s customers appreciate the investments it is making. Marc Turner said: “With the large windows and LED lighting on the machines, customers can see their parts being machined. The advanced styling and design of the DMG MORI machines is an important factor showing that we are serious about our business. A recent opportunity made possible with 5-axis machining is the manufacture of guitars from solid aluminium. Our customer is working with some very high profile musicians, opening our eyes to other business possibilities thanks to the technology we have invested in.”