Specialist precision tooling solutions provider selects Doosan vertical machining centre for its capacity, machining capabilities, immediate availability and cost-competitiveness.

Leading specialist tooling solutions supplier, Cogsdill-Nuneaton Ltd, has recently invested in a new high-performance Doosan vertical machining centre from Mills CNC.

The machine, a DNM 6700, was installed at the company’s 27,000 square foot facility in May 2018 where it is being used, primarily at this moment in time, to machine precision components for Cogsdill’s range of ZX facing and contouring head tooling systems. These components include different sized front-mounted cross slides, with slide ranges from 200mm to 900mm, which are machined from nitrided and carbon steel.

The decision to invest in the new Doosan DNM 6700 machine followed an internal review undertaken by Cogsdill into its existing CNC machine tool capabilities and, in particular, whether current milling machining capabilities were adequate the meet the growing demand from customers worldwide for its large-capacity tooling solutions.

Says Lee Donaldson, Executive Director, Cogsdill UK:

“We invest regularly in advanced CNC machine tool technologies and the audit and review highlighted a potential improvement opportunity within our existing CNC milling capabilities.”

With global demand for its larger tooling solutions on the increase it became clear to management and production staff at Cogsdill that an investment in a new, reliable and large-capacity vertical machining centre was required.

Explains Lee Donaldson:

“To ensure we acquired a vertical machining centre that matched our needs and expectations we did our homework and created a ‘key criteria’ checklist before investigating the market.”

In addition to the working capacity of the new machine other requirements included the machine’s cutting performance, its availability and price as well as the scope and scale of the technical back-up and after-sales support services provided by the machine tool supplier.

Continues Lee Donaldson:

“Although we hadn’t invested in a Doosan machine tool previously we knew that Doosan machine tools have a good reputation in the market, and that Mills CNC, the exclusive distributor of Doosan machines in the UK and Ireland, is a successful company with a significant market presence.”

Cogsdill also had direct experience of working in collaboration with both Doosan and Mills CNC as a Technical Partner – supplying advanced tooling solutions to both.

A recent example of this involved Cogsdill working in partnership with Doosan and Mills CNC to deliver a turnkey process for auto-loading facing heads, boring tools and splining tools, into a Doosan Horizontal Boring Machine (a DBC 130) for a US-based oil and gas customer.

Following an extensive search into the market Cogsdill ultimately decided on investing in a new DNM 6700 vertical machining centre.

DNM 6700: Capacity and capability

The DNM 6700 is a large-capacity vertical machining centre equipped with a generous sized work table (1500mm x 670mm) and impressive axis travels (X-axis:1300mm x Y-axis: 670mm x Z-axis: 625mm).

The machine also features a powerful, high-torque (118N-m) direct-drive spindle (18.7kW/12,000rpm).

Says Lee Donaldson:

“The working envelope of the machine was of critical importance and the DNM 6700 large-capacity working envelope enables us to machine larger components (as well as smaller components) in a single set-up. This means faster production and reduced part cycle times.

“Similarly the cutting performance of the machine was important and the DNM 6700’s powerful and direct-drive spindle technology gives us ability to achieve high-volumetric removal rates when required as well as fine finishes. It is a very versatile machine.”

To increase the machine’s flexibility still further Cogsdill, as part of its investment in the DNM 6700, also ordered a 4th/5th axis unit to be supplied with the machine.

DNM 6700: Availability

Mills CNC has at least 70 new Doosan machines, at any given time, in stock at its Technology Campus facility in Leamington. A significant proportion of these machines include its best-selling DNM vertical machining centres.

Comments Lee Donaldson:

“The quick availability of the new machine was important. We attended MACH 2018 where we visited Mills CNC’s stand and supplied them with a ‘letter of intent’ to purchase a DNM 6700. Just a few weeks after the event, once we had acquired external grant-based funding, the machine was delivered, installed and commissioned.”

DNM 6700: Price

DNM 6700 machines are competitively priced and this, in conjunction to their high-performance and reliability, explains their popularity.

Says Lee Donaldson:

“I have to say that we were presently surprised with the machine’s price. There is a lot of technology and functionality packed into the DNM 6700 and, whilst price isn’t everything, it clearly is an important factor when making any capital investment.”

DNM 6700: After-sales support

All Doosan machines supplied by Mills CNC are backed by the company’s impressive after sales service and support.

Concludes Lee Donaldson:

“Mills CNC’s reputation in the market for its after-sales support is second to none and we have direct experience of this having worked in partnership with Mills delivering a number of turnkey and process improvement projects for customers.

“Just knowing that you have Mills’ technical, applications and service back-up at your disposal inspires confidence.”

DNM 6700 in action

Since being installed at Cogsdill’s facility in Nuneaton the DNM 6700 has been used to machine front-mounted cross slides used in the company’s ZX facing and contouring head tooling systems.

These cross slides are rough machined from solid on the machine prior to stress relieving, and are then semi-finished, heat treated and ground before final finishing operations occur.

On average machining times for roughing, semi-finishing and finishing are 60 minutes, 90 minutes and 30 minutes respectively.


ZX facing and contouring head tooling systems

Cogsdill’s ZX facing and contouring head systems increase the capabilities of machine tools with live spindles, such as horizontal boring machines. The heads have a single front-mounted tool slide onto which top tooling is mounted into qualified locating holes.

The systems facilitate the machining of large castings and components that are difficult and awkward to hold and rotate, and enable a range of different machining operations i.e. external turning. grooving, taper boring, radius forming, chamfering, recessing, threading etc., to be performed in a single set-up without moving the workpiece from the machine table.

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