ABG Rubber & Plastics has reduced the machining time on plastic components by switching to a Brother BT30 three-axis vertical machining centre.
The Speedio S700Xd2 has also increased manufacturing capacity and helped cut lead times for customers in the water, food, rail, automotive, electronics, pharmaceutical and agricultural sectors.
The machine, supplied by Whitehouse Machine Tools was installed in a single afternoon. Following just two days of operator training, the machine was put straight into full production. Its performance has demonstrated that compact BT30 machining centres can provide an attractive alternative for many plastic machining applications.
The S700Xd2's high productivity is due to its rapid traverse rates of 50/50/56 m/min in X/Y/Z, Z-axis acceleration of up to 2.2g (the fastest in its class), a 1.4-second chip-to-chip tool change, and a spindle start/stop time of just 0.15 seconds. Together, these features significantly reduce non-cutting time, allowing the tool to spend around 30% more time in cut than on the previous BT40 machining centre. In addition, the Brother Speedio's 16,000 rpm spindle is twice as fast as that of nearly all other machines on the shop floor, enabling higher material removal rates.
The machine delivered a substantial reduction in cycle time on one of its first production orders, providing a meaningful productivity improvement across a high-volume batch.
ABG Production Manager Anthony Morbey said: "The S700Xd2 is not only fast, but also accurate and holds tolerance well, which is primarily down to its rigidity and excellent coolant delivery to the cutting area.
"Machining plastics is challenging because their coefficient of thermal expansion is typically around ten times greater than that of metals, so careful temperature management of components is essential."
A further advantage of the machine is its compact footprint, allowing the machine, complete with chip conveyor, to fit easily into the space on the busy 10,000 sq ft shop floor vacated by the previous BT40 machine. Despite occupying little more than two square metres of floor space, the BT30 VMC offers a generous working envelope of 700 x 450 x 380 mm.
Another key benefit is its low energy consumption. The compact machine uses around one-third of the power required by a typical BT40 machining centre and consumes significantly less compressed air. With energy representing one of the Northampton factory’s largest overheads, the efficient Brother Speedio proved an attractive investment and aligns with ABG’s objective to reduce energy consumption.
Based in Northampton, the majority of ABG’s work involves fixed-head and sliding-head turning, together with 3- and 5-axis milling, of engineering plastics including nylon, acetal, PET, PEEK and PTFE. The remainder of the company's business comes from the cutting and processing of rubber materials.