Answer to "Engineering News " Questionnaire

Question1)

Please provide some background information on your company, main activity etc.

The FAS Lathe is manufactured and marketed by FAS Machine Tools (Pty) Ltd, which is based in Pinetown (near Durban). Mr. Peter Frow, CEO of the company and a graduate mechanical engineer, identified a need for a machine that would combine the user friendliness of a C.N.C. lathe with the fast cycle times of cam-operated automatic lathes, at an affordable price.
Cam-automatics achieve fast cycle times by having several tools working simultaneously, whereas most C.N.C. lathes are sequential machines applying one tool at a time to the workpiece.
However for the cam-automatic to achieve optimum production rates, job-specific cams must be designed, made, fitted and timed. This leads to long set-up times which tends to confine the cam-automatic to longer runs.
This was the impetus that eventually led to the birth of the FAS Lathe.

Question 2)

When was the new lathe developed?

Conceptual design work began in 1990. The conventional cam-automatic technology was studied to see if the "rocket scientist" factor could be reduced.
Existing designs were evaluated and the best features from each were extracted.
In addition, each step of the setup procedure was analysed to see whether by innovative design it could be either eliminated entirely or minimized.

By 1995 a practical design was on the drawing board. This lathe which became known as the FAS lathe, embodied a number of unique features which have subsequently been patented.
The prototype was eventually completed in February 1999 assisted by funding awarded from the Department of Trade and Industry's Support Program for Industrial Innovation.(S.P.I.I.)
The machine was placed on trial in a company, specializing in the production of turned components, and proved to be a highly cost-effective machine.

With experience gained on this machine, numerous detailed improvements were incorporated in the production design, which was launched in November 1999. The first sale was to a major corporate and was secured early in 2000.
As further machines were sold and operating feedback was received from the field, additional design enhancements were incorporated.

Machines in the field have now logged many thousands of hours.

Question3)

What are the innovative features of the FAS Lathe?

Although the FAS Lathe belongs to the large family of cam-operated lathes, it is in fact a new generic type with many unique, patented features. The most striking result of this combination is that setup times are dramatically reduced, typically from half a day to half an hour. This means that the machine can be cost-effective down to small batch sizes (see Graphs)
Of the features listed, the most important in achieving these results are:

Universal Cams:
Fitted for the life of machine: no other cams need be designed, made or fitted.

Constant Feed Rate:
Feed rates once set, are maintained irrespective of spindle speed.

Infinitely Variable Spindle Speed:
Allows optimum spindle speed to be set quickly and accurately.

Micro Setting:
Micrometer adjust and hand clamp on 10 setting variables.

Push Button Setting of Cycle Time:
Allows Cycle Time to be altered in seconds.

Push Button setting of Cam Timing:

Allows alteration of Cam timing in seconds.

Memory Setting:
Tool parameters are stored with form tools enabling the first component of a new batch to be within, or close to specification.

Constant Deadstop Operation:

Allows consistent holding of diameter tolerances. Diameters may be altered without the need to re-adjust deadstops.

Synchronized Threading:
Components can be threaded by setting of pitch and length variables on the Synchronized Threading Attachment. Thread production is unaffected by changes in spindle speed. The entire threading sequence including indexing, is pre-timed and synchronized to produce a wide variety of different threads.

Ease of Optimisation:

Once in production, individual machining parameters can be altered to minimize cycle time.

Question 4)

What kinds of volumes can the machine produce?

As the graph indicates, the machine is cost effective across a very wide range of batch sizes: Anything from 50 to 500 000 and upwards.

Question 5)

Are you planning to market the machine abroad as well as locally?

Export of FAS Lathes has commenced.

Question 6)

What has been the reaction from users and potential clients of the FAS lathe?

At the launch of the FAS Lathe in November 1999, the machine was demonstrated being changed over from a brass nozzle with external thread made from hexagonal material to a round tapered steel nut with knurl and internal thread. The entire changeover took just 15 minutes.

The following comments were noted:

"That would have taken at least 4 hours on my existing machines even if I already had the cams"
"This takes all the hard work out of setting."
"We have visited international machine tool trade fairs and there is nothing like this available."
"We think the price is very reasonable."
"You've got a winner here."
"Why don't you market this more strongly."
“A brilliant concept”
“I was sceptical of the claims until I saw with my own eyes.”

Question 7)

How do you view the marketability of the FAS Lathe, Do you expect it to be hugely successful?

We believe that the machine has the potential to bring about a global shift in production turning economics, and that in time the FAS Lathe and it's derivatives will replace many existing machines.

Question 8)

Which Industries is the FAS Lathe aimed at?

The FAS Lathe is expected to penetrate the following markets:

• Existing Cam-Automatic users who will recognize the cost-effectiveness of the machine in terms of its rapid changeover time and reduced dependence on tool setting and cam design expertise.
• Existing C.N.C. Lathe users who have been unable to access those markets serviced by Cam-automatic users because of the technical demands associated with running such machines.
• Users of turned components who have formerly subcontracted their requirements, but who will now find in-house manufacture accessible.
  

Question 9)

What about Special Applications?

A number of machines have been sold with special attachments and tooling to suit unusual applications. FAS Machine Tools has the design and engineering capability to enable customisation of the basic FAS lathe to meet specific customer requirements.

Question 10)

Anything else to add?

The FAS Lathe is a new generic type of production lathe. No comparable machines are currently available.