In a significant investment for the future, Metalex Manufacturing located in Cincinnati, Ohio selected Starrag to supply a large-capacity, multi-axis Droop+Rein portal-type machining center for their new Center for Advanced Large Manufacturing.
The machine – the largest ever installed by the Cincinnati-based contract manufacturer – will provide it with the ultimate in flexible production capacity to meet all Metalex’s foreseeable demands in terms of producing highly-accurate milled and turned workpieces in a single set-up.
Indeed, the six-axis Droop+Rein T series machine is projected to not only satisfy existing projects but its extraordinary machining envelope of up to 709 inch table length, 374 inch between the columns and 276 inch under the spindle will certainly also attract new work – thus further ensuring Metalex’s success in the market of high quality manufacturing.
The portal type milling and turning machine – which is being especially configured to meet Metalex’s current and future needs – offers an expansive 748 inch in X- and 354 inch in Y-axis. The 276 inch vertical clearance is covered by the 118 inch of ram stroke (Z-axis) and a continuously moveable crossrail of 217 inch (W-axis). The C-axis integrated in the ram with infinite rotation and the +/- 203 degrees Fahrenheit swiveling B-axis of the universal fork-type milling head complete the 6-axis.
The impressive 136 hp main spindle transfers up to 66,372 lbf in to the heavy vertical and horizontal milling head. A heavy duty fork-type head, a spindle cartridge change fork-type head - both to enable 5-axis operation - and a slim spindle extension round up the initial milling head configuration. All heads will be designed, built and tested by Droop+Rein in Bielefeld. Furthermore, the machine will be prepared for more heads to be fitted in the future as new jobs arrive. The versatile 400 pockets robot tool magazine ensures automatic loading of 3 different tooling systems into the selected milling and turning heads.
A distinctive feature is the table design. The X-bed carries two 236 by 315 inch tables that can be operated separately under the spindle while the other one is (un-)loaded outside the machining area. Coupled ‘in tandem’ the tables can be extended to an enormous length of 709 inch for machining extra-long workpieces. In addition, each table holds an integrated 236 inch rotary table that utilize the 2 x 149 hp main drives to turn components of up to 440,925 lb weight (using one of the turning tool holders provided in addition to the milling heads) or to position as a C-axis for high accuracy milling and drilling operations.
The result will be the ultimate one-stop precision machining source for extra-large components with complex geometry that require precision tolerances.
Starrag meets Metalex’s big machining plans
with large scale six-axis Droop+Rein portal machining center
Established in 1971, Metalex is a performance-driven contract manufacturing company, specializing in producing high-quality complex workpieces for a wide range of market leaders in the Aerospace, Energy, Marine and Consumer Goods industries.
Metalex desire to source a machine that would not only satisfy current production needs but also meet all projected demands in the years ahead saw it contact with a number of machine builders, including Starrag which in the past has supplied it with a number of machines (a Dörries vertical turning lathe and two Starrag STC horizontal five-axis machining centers).
According to Droop+Rein Product Sales Manager, Heiko Quack: “We sat down with Metalex to discuss what was needed - in short: a very flexible, large-capacity and high-accuracy machine with 5-axis capability that would efficiently accommodate a variety of parts in a range of materials and produced to tight tolerances.”
Investing in the future
Metalex located in Cincinnati (Ohio) has ordered a 6-axis gantry machining center from the Starrag Droop+Rein T series for the new "Center for Advanced Large Manufacturing". It is the largest investment in the company's long history.
