Seattle-based job shop reduces cycle time by 50 percent and tooling costs by 60 percent
GROB 5-axis machining center with Sinumerik CNC makes it possible
Honeycutt Manufacturing, a Mukilteo, Washington job shop located near Seattle, is in service to the aerospace, marine and general industrial manufacturing markets. Recently, they made a major investment in a GROB G550T 5-axis universal machining center, and to say the purchase was a “game changer” would be an understatement.
This family-owned and operated machine shop was running 2-axis turning machines and VMCs for a number of years and doing quite well. The business came largely from aerospace-related companies in the local supply chain to that major OEM.
As General Manager Nick Honeycutt explains, “We didn’t feel we had the workload for a 5-axis machine at the time our local machine tool dealer, Vince Selway of Machine Tools NW, approached us about the GROB machines. We have a long and mutually beneficial relationship with Vince, so we were certainly interested in his suggestions.”
Honeycutt subsequently purchased a 4-axis HMC and the results were acceptable plus a base savings had been realized, but then a particular job opportunity presented itself and the shop purchased its first GROB, a G550T 5-axis machine, with advanced machining technologies to move his shop forward.
After the commissioning and training, including sessions with the Siemens CNC account manager, Daniel Vitullo, who gave the operators assistance with the SINUMERIK 840D sl control, the first parts were produced to spec on the very first day of run-time.
Reducing machining steps drives efficiency
In two weeks, Honeycutt Manufacturing brought a variety of customers into their shop to see the GROB machine in action and the company was immediately awarded additional work.
As Honeycutt explains, "With GROB, we have reduced machining operations from six to two, shortened cycle times by 50 percent and cut our tooling costs by 60-70 percent". Within 30 days, the shop was ready to buy its second GROB machine tool with SINUMERIK CNC and plans are in the works for an addition to the building that will house 3-4 more machines.
Aluminium, Inconel and titanium
While much of the aerospace work here is aluminum with
very high removal rate, a further advantage emerged with
the GROB-Siemens combination. On jobs involving Inconel
and Titanium, the power of the machine plus the 0.0006”
typical accuracies and 32Ra finishes they were able to
achieve, won the machine shop even more work, according
to Honeycutt. These levels of accuracy and finish are
critical on parts produced, which range from aluminum
leading edge to titanium elevator controls, lab
devices for precision measurement, and commercial as
well as pleasure boat components.
Vince Selway of Machine Tools NW, the machine tool dealer for GROB in the area, is a long-time partner to Honeycutt. “My father sold machines to Honeycutt, so we have a long history with the shop.” He detailed the sale of the first 5-axis machine, noting that, “… it worked so well that they were so excited by what they witnessed on their shopfloor, as it performed aluminum hog outs at such an incredible rate, they could barely keep up with the chips flying. Even better were the accuracy, finish and speed being achieved on the really tough-to-machine materials.
Advanced Siemens CNC is the clear choice
Andy Krupp, an application engineer at GROB and responsible for Honeycutt, explains: "The horizontal design of the GROB machines is unique and has a number of benefits over the usual machine layouts. At Honeycutt, our 5-axis machining center helped to improve parts production for aerospace applications while meeting top quality standards."
Andy Krupp, a universal machine applications engineer at GROB, elaborated on his company’s focus for this project. “GROB is a global supplier to the automotive, aerospace, mold-and-die and energy industries. We’re involved in many emerging technology developments, such as e-mobility, too. We build our 5-axis machining centers for our metalworking customers, plus we can supply full automation cells to meet their specific production requirements. This can be a dedicated, high-volume solution or a highly flexible solution for a low-volume, high-mix production. The GROB horizontal 5-axis design is unique and offers many advantages over conventional 5-axis vertical machines on the market. All these machines are built at our factory in Bluffton, Ohio. On this Honeycutt project, the addition of our 5-axis machines helped to significantly improve their aerospace part production, while maintaining the highest quality standards.”
Sinumerik 840D sl is the only control for special complex machining options we’ve developed on our machines, including multi-tasking mill-turn, skiving (used for gear production), high-end hobbing, cross-feed spindle configurations and more.Andy Krupp, applications engineer at GROB
Krupp continues, “One of the great things about using the SINUMERIK 840D control is its ease-of-use. Training people who have used other brands of CNC and bringing them to a comfort level using Siemens has actually been quite simple. Inputting information and using the control seem to be much more intuitive than with other brands and we’ve found this cuts the learning curve, significantly.”
“The capabilities of the GROB machines with Siemens helped sales at Honeycutt, almost immediately,” Selway mentioned. “My customers who are most successful are the ones who follow the proper protocol for training, invest in it and take the time to do it properly. They go to the factory, meet the people at GROB, get a deep understanding of machine functionality and diligently complete the training for their operators. This all contributes to more success with the machines, in a much shorter time span. The owners of Honeycutt Manufacturing were motivated and took the time to learn. It’s clearly paid dividends at their company… and mine,” Selway muses.
Intuitive operation of complex machining functions
On the 5-axis machines at Honeycutt, the Sinumerik CNC is outfitted with the GROB-4 Pilot control panel, allowing the machine builder to incorporate additional applications onto the 24” operator interface (HMI).
Nick Honeycutt further observes, “The Siemens CNC was a relatively easy learn for our operators, due to the training we received from GROB and Daniel from Siemens. We had a lot of experience with other control brands, but the speed and power of the GROB 5-axis machines with SINUMERIK made the higher-level CNC very necessary to execute our complex operations on a single machining center.” He also noted how the Siemens control on the GROB machines easily interfaces with the Honeycutt CAD and CAM platforms they use here.
Honeycutt, along with his brothers Steve and Tim, run the company their father founded in 1980. The shop operates multiple shifts, seven days a week, and is continuing to expand to meet the additional business being generated by the GROB 5-axis machines and other services they provide, including waterjet and laser marking. Honeycutt has a network of local machine shop partners, who provide swaging, certified aerospace and marine welding, precision gun-drilling, wire EDM, super-finishing, and large-scale as well as flat precision grinding services.
John Meyer, Siemens USA