The CNC sliding head lathe's ability to machine components in a single set up has eliminated the need for second operations, driven tooling performs milling, slotting and drilling operations.
Hullmatic Engineering Co, based in Earls Colne, Essex is a major player in the UK turned parts industry, predominantly for clients in the diesel automotive sector. To help it produce 18 million components a year, the company relies on its selection of 10 Deco CNC multi-axis sliding head lathes from Tornos. Currently celebrating its 30th anniversary, Hullmatic was a family-owned business until a management buyout team led by director Peter Pledger, took over the reins last year.

The new team is already building on Hullmatic's success as a supplier to the commercial diesel automotive sector, with customers that include Delphi, Perkins and Caterpillar.

The 72-employee company is a specialist at bar turning and has an impressive array of machine tools.

As well as Deco sliding head models Hullmatic owns over 20 single spindle automatics, over 20 multi-spindle automatics, five fixed head CNC lathes and five rotary transfer machines.

The first Tornos machine arrived following a visit to the UK's MACH 1996 machine tool show.

It is testament to the technology, reliability and performance of the Deco CNCs that the company proceeded to purchase a further nine models over the following six years.

The Tornos Deco 2000 models currently on site include four Deco 10a machines, three Deco 20a machines, one Deco 13a, one Deco 13bi and a Deco 26a.

All but one of the Deco CNCs is fed using Tornos Robobar bar loaders.

'The big advantage the Deco CNC machines provide is the ability to machine components in a single set up'.

'The machines have eliminated the need for second operations entirely'.

'We use the driven tooling extensively for milling, slotting and drilling operations,' explains Peter Pledger.

Batch sizes on the Deco machines range from 500- to 10,000-off, with selected machines dedicated to producing families of parts.

This particular strategy helps keep set-up and changeover times to an absolute minimum.

Programmed off-line, only one operator is required to oversee four Deco CNC machines, which operate day and night, five days a week.

Components are machined from steel and non-ferrous materials to tolerances of around 0.015mm.

'The Deco machines have been fantastic for us'.

'Their consistency in terms of roundness, concentricity and surface finish is second to none'.

'A reject is a really rare occurrence'.

'Also, we find the machines are very responsive'.

'Over the years we have had experience of programming a lot of turning machines, but when it comes to producing a first-off from a new program, the Tornos Decos have been the best I have seen at meeting demanding drawing tolerances and characteristics,' continues Pledger.

Hullmatic purchased its Deco machines to complement the company's existing turning technologies'.

''Whatever turning machines we buy have to be competitive,' adds Pledger'.

''If the sums did not work out for the Decos then we would not have proceeded, but in terms of saving second operation work, the benefits have been enormous.' Hullmatic also says the multi-tool turning is a major advantage in maintaining competitiveness.

It allows the company to perform roughing and finishing operations 'downstairs', while a form tool is used 'upstairs''.

' 'We have a big mix of machines and technologies,' concludes Pledger, 'which allows us to be highly responsive in terms of lead-time, and the Tornos Deco machines play a large role in helping us meet our deadlines and keep our customers happy.'