Based Pewsey, Wiltshire, Apogee Industries supplies complex parts to the oil and gas, aerospace, motorsport and defence industries and has built a reputation for making complex, intricate and high tolerance parts in exotic materials to high standards. Director William Chappel explains: “We produce components for companies around the world, working in partnership with them to develop a lean and efficiently manufactured product. In every case we need to achieve high quality and accuracy, whether it is a single one-off prototype or a production run of thousands.”
Apogee Industries currently employs 4-axis machining centres and turning centres with driven tools, together with a high level of engineering input. This approach requires numerous set-ups and many bespoke fixtures. Says Chappel: “Many of the parts require between four and nine set-ups, along with the associated jigs and fixtures for each operation. The result is an unacceptably low level of overall spindle run time offering very little optimisation and hence resulting in limited output. We anticipate that the increase in productivity through the implementation the NTX 1000 second generation will allow an additional up time of 70%.
“The DMG Mori NTX 1000 2nd Generation will replace four ageing machines and is expected to dramatically increase spindle run time. This is where we gain critical revenue to invest in new equipment. The DMG Mori NTX 1000 2nd Generation is scheduled to run our monthly batch requirements through the evenings while the small quantities of complex jobs can be watched and manned during the daytime. In addition to the extra machining time, savings will be made on maintenance, associated running costs and duplication of tooling packages.”
With the machine’s arrival, Apogee will bring a number of subcontracted processes in house, from gear cutting, broaching keyways and splines, to deep hole drilling and a limited amount of gun drilling, thanks to the 70 bar coolant pressure.
Some of the parts that the new machine will tackle at Apogee Industries
The DMG Mori NTX 1000 2nd Generation has 65 mm (an option) bar capacity and can handle a 430 mm diameter by 800 mm long billet. It is also equipped with a B-axis head that delivers 20,000 rpm (also an option), and a 10-station lower turret with a built in motor offering 10,000 rpm.
The machine can run lights out and unattended, courtesy of the bar feed and in-machine travelling workpiece unloader that negates the need for an operator to handle components mid production, so delivering an extra production of 60% per week. And to ensure quality, repeatability and reliability, the machine is fitted with linear scales, a Renishaw probe and tool breakage detection, allowing Apogee to probe in cycle, validate parts and update tool offsets automatically before their removal from the machine. The machine can also switch to sister tooling, if needed, and also ensure parts are rejected, if there is a tool failure.
Fitted with CELOS, the NTX 1000 2nd Generation will integrate with Apogee’s existing job management system. The company will also have the CELOS PC version, enabling its engineers to access drawings, images of the set-up and notes, and to schedule jobs from the office.Adds Chappel: “CELOS will be very important to us, as we work in a dynamic environment where we have to respond very quickly to our customers’ needs and requests. It will enable us to rapidly re-tool and set-up for repeat jobs. Previously, we had to take immense care on the multiple set-ups, produce spare parts for each operation and endure an overly high scrappage rate but, with the NTX 1000 2nd Generation, the requirements for jigs and fixtures will be effectively removed and we will be given the ability to manufacture the precise amount of components required.
“The machine already has a full production schedule on arrival, due to on-going projects. Naturally, reliability and service will be of paramount importance and DMG Mori’s transparency in service and repair times, as well as the obvious build quality and precision characteristics of the machine, is very reassuring.”
Chappel adds that the investment indicates the start of a big change at Apogee, which has been growing organically for 10 years at the rate of 15-25% per year, saying: “British manufacturing is based upon high technology. As a company, we should always strive to invest in the latest equipment to increase efficiency, productivity and overall value for the customer. This predominately leads to an advanced and automated manufacturing space. The NTX 1000 2nd Generation is the start of this transformation for Apogee.”
