DN SOLUTIONS

Market leading precision subcontract specialist AVPE launched ambitious growth plans in 2011and experienced a dramatic transformation assummed up below over a period of three years. An increase in floor space has helped the company reorganize its manufacturing operations, create flexible manufacturing cells and, as a consequence, improve work flow and production efficiencies; Investment in high-performance machine tools and ancillary equipment, and sophisticated CAD/CAM software has improved quality and helped reduce lead times and operational costs; Investment in multi-tasking machine tools has enabled the company to secure more high-value contracts for machining small series complex, high-precision parts; Behind such growth and development of the company were Doosan machine tools such as DNM 400 vertical machining centers, Puma 3100 turning canter and VC630 5AX machining centers.

Correlation between Continuous Development and Doosan Machines

It was at the beginning of 2013 that AVPE purchased its first Doosan machine tool. Through the installation of a DNM 400 vertical machining Centre, it was able to improve its machining capabilities and capacity. This machine, supplied with a4th-axis unit as part of the deal, was acquired primarily to machine aluminium interior cabin parts for an aerospace customer.
Says Steve Eccles, AVPE’s Technical Director: “Our existing milling capabilities were under pressure and couldn’t be relied upon to achieve (consistently)the part accuracies, surface finishes or the delivery times required. We researched the market and identified the Doosan DNM 400 as being the ideal machine to meet our requirements. The machine’s rigid design and build, its advanced spindle technology, its cost-competitive price and the number of positive endorsements from customers who had invested in DNM machines, all helped in our decision making process.” He went on to say, “We were so impressed with the DNM400’s performance that we ordered an identical model soon after - and this was installed in May2013.”
Virtually at the same time as the first DNM 400was being installed at AVPE’s facility, negotiations were well underway regarding the company’s investment in a large-capacity Puma 3100 lathe. Explains Steve Eccles: “Puma lathes have a good reputation in the market for their accuracy, repeatability and reliability. So it was not a difficult decision for us to make. The Puma 3100 helped us increase our turning capabilities, and the Puma3100LM we selected gave us extra manufacturing flexibility and the ability to machine parts to completion in one hit.” The Puma 3100LM lathe was installed in April 2013 and AVPE acquired a second Puma lathe (a Puma 3100) in December2013. Both lathes are being used to machine a range of metal and plastic aerospace parts.

5-Axis Technology for High Value-Added Machining

The company that was concentrating on multitasking machining technologies and improvements in productivity began to make bold investments in 5-axis machines for improved performance and high value-added machining as it signed a contract to machine aluminium fuel injection connectors for A380 aircraft. Given the reliability and outstanding performance of Doosan DNM 400 and Puma 3100 machines that we were using on the ground combined with the positive relationships we built with the relevant local dealer during the purchase and installation processes, Doosan machine tools were a priority consideration for us in our 5-axis machine tool purchase process.
We were looking for a universal 5-axis machine that could provide us with both 3 + 2 positional and full simultaneous 5-axis machining capability. We wanted the machine to have a good sized working envelope so that we could machine large, small and/or multiple jobs in one set-up, and we needed the machine to be competitively priced and to be available for immediate delivery. “Against all our search criteria the Doosan VC6305AX came out on top and in July 2013 the first machine was installed.” A second VC630 5AX was ordered and installed a few months later.
VC630 5AX machines have a rigid construction, exhibit excellent vibration and heat dissipation characteristics and punch well above their weight. They are able to handle large parts (730mm x500mm), and are equipped with a 630mm diameter table, a competitive edge over competitor machines. VC630 5AX machines use the most advanced level of Heidenhain iTNC 530 control with 1000 block look-ahead contour capability for reliable high-speed machining. The machines are also equipped with powerful, high-torque12,000rpm 32kW spindles, and feature the dual contact ‘Big Plus’ face and taper configuration that ensure high accuracy even when rough machining tough and difficult-to-machine materials.
AVPE’s 5-axis machines operate virtually around the clock. They are being used to machine both MRO and small series production parts to exacting tolerances and stringent surface finishes. As a conclusion Steve Eccles reiterated the importance of investments in machine tools for continuous development of his company, “our company is stronger and more flexible than ever before through acquiring advanced multi-tasking machine tools like VC 630/5AX and upgrading our machining capacity and capabilities.”