The machine that catches the eye of visitors to the new 2,400ft2 premises of Hertfordshire-based precision sub-contractor Verulam Engineering is the first UK-built Ajax AJV 700 vertical machining centre
(www.ajax-mach.co.uk). Featuring a 10kW 10,000rev/min direct-drive spindle and a 24-position tool magazine, this machine is producing a range of complex aerospace components for two of the five new customers won by Verulam in the first half of this year. Alongside it is an earlier AJV 700 — also mainly used for new work, including prototypes in small batches.
Managing director Len Cooper says: “The levels of accuracy, repeatability and surface finish that we can achieve on the new work have proven to be a real winner for us.” In addition, switching a batch of components for the ultrasonics industry from another VMC to the AJV 700s allowed the cycle time on these aluminium components to be reduced from 14 to 11.5min — thanks to the 48m/min rapid-traverse rate, faster accelerations and shorter tool change times.
“What is significant is that we saved a whole shift on the batch just through better floor-to-floor times. However, with so much swarf produced, the integral coolant flushing within the working area and easy chip extraction mean that the machine never stops except for loading and unloading. On the other VMC, we would constantly be holding up production to clear the build-up of swarf.”
When the company transferred production into the new facility in Luton over Christmas 2012, it doubled the available floor space, providing ample room for the two Ajax machines. A mezzanine floor with offices and a rest area for the seven members of staff was completed in May. Verulam director Robert Taylor says: “Managing the growth of the business in a restricted workshop was becoming difficult, because we have a strict policy of being truthful on delivery promises. Our customers know that parts will arrive to the agreed date and will always be delivered personally by one of our staff. This is important; it keeps us in touch.”