Quickgrind streamlines speedy path to success

As a small start-up company, Streamline Cycling manufactures composite wheel rims to enhance the aerodynamic performance of bikes. Set up by Daniel Cain, the founder of Streamline Cycling, the Lasswade based company turned to the University of Strathclyde operated National Manufacturing Institute Scotland (NMIS) and Quickgrind to help accelerate the growth and performance of the business. Now, Streamline Cycling is being supported by NMIS through an SME voucher funded by the European funded ‘Machining 4.0’ project where NMIS is the UK partner.

Discussing the foundation of the Scottish business, company owner Daniel Cain says: “We make the ‘Air System’, which is a product that comprises of a base rim that comes complete with a hub and spokes that can be fitted quickly and easily with aerodynamic covers to bicycles. There are two options at the moment, one of which is a 64mm depth cover – this is the depth from the wheel rim inwards, and we also have a full disc that goes onto the rear of a bicycle. Essentially, what these products are doing is adding aerodynamics without having to buy a whole new set of wheels, as wheels can be very expensive.”

“By adding the discs to the wheels, the main benefit is aerodynamic gains. Cyclists are enthusiastic about the aerodynamics of a bicycle and achieving the minimum power input for the maximum speed. By adding these covers, riders can either put in less power for the same speed or go faster with the same power input. The 64mm version adds a little bit of speed, but if it is too windy you would not want to ride with these as you may get blown around. It is the same with the full disc, you can have these on the rear wheel, and they will add a ton of speed. There are two products, and the main product is the air system which is more for racers, triathletes and time trialists. There is another option which just features the rear covers that can fit onto any rear wheel, so anyone can fit the covers an

d save a lot of money compared to fitting a fixed disk.”

The company built its own 3-axis CNC machine tool router for the manufacture of mould tools from tooling boards and the trimming of carbon fibre parts. Following this, Daniel had a number of online calls with Kareema Hilton, the Lightweight Machining Theme Lead within the Machining and Additive team at NMIS and Mark Aspinall from Quickgrind, an industry-leading manufacturer of cutting tools.

Looking at the manufacturing process, Daniel adds: “I realised quickly that I needed to make a mould to make these carbon fibre parts. The first step was to build a CNC and at the end of that, I had a lot of questions. The carbon fibre is laid into the moulds that I have made and then a vacuum system is applied, and the parts go into an oven for an hour and when they come out, they are trimmed with a CNC router. The router trims the outside of the parts and the inside, it also cuts out the attachments as well.”

Referring to the project, Mark from Quickgrind says: “Streamline Cycling invited me to Edinburgh to look at the workshop and I was pleasantly surprised to see the company was curing its carbon fibre products using its own Autoclave. We studied the routing machine and fixturing and discussed some improvements with regards to workholding and subsequently the most suitable cutting tool solution and the ideal cutting geometry based on the spindle power & speed, simultaneously taking into account cost considerations that are critical for small business owners.”

Daniel is using Autodesk Fusion 360 CAM for programming his router and we discussed how to use different cutting data, tool paths and entry into cut methods to achieve the best tool life and quality of machined surface when trimming and machining holes.

Throughout this project, Streamline Cycling has worked with Quickgrind and NMIS, which is part of the High Value Manufacturing (HVM) Catapult. Referring to the evolution of the relationship, Daniel adds: “I met Kareema at NMIS, and she put me in touch with Mark at Quickgrind – both of them were super helpful, especially as I had a thousand questions around building my routing machine. I had a lot of questions from Mark at Quickgrind regarding the tooling, and he helped me with some tools that got me going. He came along and looked at the CNC and gave me some suggestions for improvements that I could make, he helped with the tool paths and the speeds and feeds.”

Looking at the specific problems with composite machining that Quickgrind helped to resolve, Daniel adds: “My main problem initially was the workholding solution. I started with a rogue solution of just holding the part while

it was being machined. Quickgrind gave me some suggestions such as a vacuum workholding system to hold the part in place. The second issue was the tools. What I was finding with the tools that I was using was that I would have a lot of fraying of the material as I was cutting. The Quickgrind tools and the tool paths resolved that issue straight away. For the 64mm product, the toolpaths are quite complicated – Quickgrind helped you to work out what was the best machining strategy to speed up the process, improve quality and minimise any bench finishing. There is a balance between how fast we can make the products and also the aesthetic finish, as it is a consumer product.”

Utilising Autodesk Fusion 360 CAM for programming the router, Streamline Cycling was informed by the Quickgrind experts on how to apply different cutting data. This included tool paths and entry into the cut to achieve the best possible tool life whilst improving the quality of the machined surface when trimming and machining holes.

For the machining of the mould tools from tooling board, Streamline Cycling used the 2-flute Alligator range of bullnose and ballnose cutting tools from 3 to 12mm diameter from Quickgrind. For the trimming of the carbon fibre components, Streamline Cycling uses a 3mm version of Quickgrind’s application-specific routing tools. This has been designed for the machining of carbon fibre and glass fibre-reinforced polymers.

“From Quickgrind’s perspective, they will have seen a lot of this type of machining before, so they were 100% on it from a tooling perspective with regards to what tools are best suited for this type of job. The tool path around the edge isn’t quite as complicated, but some of the ideas from Mark at Quickgrind helped to extend tool life, such as moving the Z-axis height of the tool when cutting around the perimeter of the rims to prolong the tool life,” adds Daniel.

“Overall, the experience of working with Quickgrind and NMIS has been excellent. They didn’t need to help me, as I am a super small company – it’s just me manufacturing these parts. So, for them to reach out, provide tools and offer assistance to help me make parts faster, speed up the process and improve tool life has been fantastic,” concludes Daniel. 

ITC is blooming brilliant for flowerbox manufacturer

Founded in 2000 by a father and son team, Bloom in Box was initially set up as a injection moulding business applying its combined 50 years of experience a handful of manual machine tools. Move forward 22 years and David Reardon has taken the reigns from his father, been joined by his children and the company now manufactures a complete range of its own product lines utilising its expertise in injection moulding, toolmaking and design. 

In its infancy, the Burscough business was working like every toolmaking business – making products for customers in a B2B environment. Now, the company produces scoops and measures for the food & health industry, security fencing and wall spikes, laundry pegs, face visors and of course the floral range of bottle bouquets and the Bloomie living vases from where the company gets its name – it is also developing new medical and PPE product lines. All product lines are produced from recycled materials and are manufactured in-house at the Lancashire facility with support from Tamworth cutting tool manufacturer Industrial Tooling Corporation (ITC). 

The small family-run business produces more than half a million scoops and measures a month, and receives more than 300 orders a day for its security spikes and laundry products and that’s before considering the extremely popular floral side of the business and other projects like run-flat systems for cars. One challenge the company had was with its cutting tool supply, recalling this, Owner and Co-Founder of Bloom in Box, Mr David Reardon says: “We were a small business with a Hurco VM10i machining centre and we used a couple of different and well-known tooling suppliers, none of which supported us fully as a small business. It was around 5-6 years ago we upgraded the machine to a larger Hurco VM20i 3-axis and we still had several sales reps that would suggest tools that would never fully resolve our issues – until we met Gary Murrey from ITC.”

It was the attention to detail and the time spent supporting and trialling the tools at Bloom in Box that really impressed David, as he continues: “Gary visited us and he helped us with tool set-ups, trials and advice – he put the effort into customer support. The attention to detail and picking the right tools for our applications yielded huge benefits for our business, it wasn’t just the ITC service that was far superior to other companies, it appeared the products were on a different level too.”

Predominantly machining P20 tool steel, Bloom in Box initially trialled the Widia M1200 face milling platform for rough machining. With impressive tool life and metal removal rates on rough machining applications, the tool proved a major success and the company adopted both the 32 and 40mm diameter variants with 7mm inserts. This paved the way for the next tool to be implemented at the environmentally conscious business that has a 40kW solar panel facility on the roof to run the majority of equipment in its machine shop.

Progressing from the Widia M1200 face mills, the family business was recommended the Widia VXF high-feed milling line. Recalling this intervention, David continues: “We were spending a considerable amount on solid carbide tools and in the injection mould industry, everything is tapered. This meant that we were unable to engage the full tool flutes and we noticed a lot of wear, but we also noticed a lot of waste, as we weren’t using the whole of the tool. To negate this issue, Gary suggested we try the Widia high-feed indexable series instead of solid carbide tools. We applied the VXF 07 16mm diameter and VXF 09 35mm diameter range and noticed a marked difference in performance and surface finishes with much higher feed rates and shorter cycle times, but more importantly, there was a huge reduction in our tooling consumption and costs.”

Now, almost all of the cutting tools at Bloom in Box are supplied by ITC as well as the robust machine vices from Kemmler. As David continues: “We have standardised our tool inventory in the machines now. This is mainly tools from ITC. The machines are set up for ITC tools with ITC’s Kemmler vices and our Autodesk PowerMill CAM software has all the parameters of the ITC tools loaded into the tool library, this makes set-ups and programming very simplistic.”

The company now applies a complete raft of ITC tools throughout the business with ITC’s solid carbide 2162 ball-nosed end mill range proving perfect for profiling intricate parts. The company also uses ITC’s 4052 taper ball nose tools, 6051 and 6071 end mills series, and the 2002 and the 2012 series of ball nose tools for aluminium alongside a multitude of Widia tools that include the GP end mills. 

More recently the company has also invested in the BIG KAISER HMC hydraulic power chucks. Referring to this, ITC’s Gary Murrey says: “Bloom in Box is a company that machines injection mould tools that demand exceptional surface finishes. To improve the rigidity and stability of the tools, I recommended the BIG KAISER HMC power chuck and the BIG KAISER Mega 6S collet chucks to achieve the desired surface finishes and also improve tool life. Initially, David was sceptical, but after a short trial, he was hooked on the benefits of the HMC chucks.”

Adding to this, David says: “Our secondary hand finishing reduced significantly after we adopted the BIG KAISER HMC chucks and this saved us a lot of time and labour resources. We use a lot of tools with a long-overhang for reaching into cavities and difficult-to-reach surfaces, these applications are naturally less robust and stable. The BIG KAISER HMC chucks vastly improved the tool stability and run-out to deliver impeccable surface finishes.”

With four Victor injection moulding machines, a FANUC injection moulding machine and three FANUC robots, the company runs its high-tech facility 24/7. Regardless of its around-the-clock running, Bloom-in-Box is aiming to become carbon neutral over the next 12-18 months. It works with all-electric machines to reduce power consumption and emissions. Investing in state-of-the-art production equipment and solar energy equipment the company is currently calculating its carbon emissions at less than 10 tonnes of CO2 per year – the ultimate goal is net zero.

Furthermore, the company has developed innovative techniques to work with food-grade approved polypropylene, which is 100% recyclable. It is also exploring opportunities to work with compostable plastic. Concluding on this, David says: “We take our environmental responsibilities very seriously and we use recyclable materials in all our product lines as well as having a major drive to be carbon neutral. With regards to the machine shop, we run it from our solar power and have innovative products from ITC that help to reduce our machining times, power consumption and costs to improve our productivity and throughput – it’s a huge help to our business.”

Looking for the optimum tool

What do engineers want from their cutting tool manufacturers? Manufacturers are expected to provide optimal cutting tool solutions for an application. How can this be defined for a specific application?

Standards must be set to achieve a formidable solution. Cutting tool standards are also defined by principles to enable customers to choose the best possible tool for a given application. Technical literature often states one tool or another as being optimal for an application. Therefore, a clear definition of optimal conditions is essential.

The criteria for finding the optimal cutting tool depends on various factors. The type of manufacturing process (short-run, large-scale, mass), product range, material type, machinery used and cutting strategies are all factors that have a direct impact on the manufacturer’s selection of the most effective tool. The consumer is interested in a tool that guarantees the highest performance levels. This can be achieved by optimising the tool geometry and producing the tool from the most relevant cutting material grade. But the chosen geometry and grade are key elements associated with the type of machined material. So, what is the ideal tool for cutting? An example of an effective tool for machining cast iron, will not be the best solution for machining heat-resistant superalloys. 

Manufacturers are faced with constant dilemmas for machining vast choices of workpieces of different shapes and dimensions. The profile of a given application may dictate a long-reach tool, whereas in other cases the large overhang of the tool will have forced limitations that decrease machining stability that inevitably affects performance.

Selecting the optimal tool is one segment of many that relate to the core of the problem critical for all machining processes, which no doubt maximises how to machine profitability. To reach this goal, various interdependent factors are considered such as the effective use of the machine, competent process planning, available work-holding fixtures and tool stock management. All factors are subject to optimisation, and finding the appropriate tool may prove to be an integral link to accomplishing the task. 

Modern production techniques feature highly engineered CNC machine tools with advanced capabilities. New-age premium machines are costly and reduce machining cycle time to diminish production costs. An ideal cutting tool should provide maximum productivity in combination with reasonable and stable tool life. To determine the appropriate solution, tool manufacturers develop advanced cutting geometries and new cutting material grades that enable reliable cutting at high metal removal rates (MRR) for diverse types of machining data. As the tool is expected to enable effective machining of different engineering materials, the geometry and the grades should be optimised accordingly.

Decreasing machine downtime is one more way to reduce production costs. The appropriate markers that relate to tool attributes such as ensuring tool availability and minimising setup time, can greatly contribute to the solution. Tool delivery is crucial for replacing ‘optimal’ with ‘suitable’. 

By saying, ‘the best tool is the one you have at hand’, one can understand important metalworking principles, making the ideal tool readily accessible.

In a perfect world, the ideal tool facilitates machining various workpiece shapes on long or short-reach applications without loss of performance. Tool customisation is an additional parameter for finding the optimum solution.

Advanced machines are expected to integrate optimal machining strategies. These strategies are planned, programmed, checked and verified in a virtual environment of computer-assisted engineering (CAE) systems well before the process begins on a CNC machine. Therefore, the right tool should have an appropriate virtual component, a digital twin that can be embedded into CAE systems.

The wide array of ISCAR’s new products, introduced in the NEOLOGIQ campaign, is aimed at optimising tool solutions for modern metal cutting applications. The NEOLOGIQ principles are conveyed through the new tool and insert geometries complemented by advanced grades. Among the many new developments, there are tools for Swiss-type lathes and multi-tasking machines.

Stainless steel and non-ferrous metals are common materials for manufacturing miniature parts in the medical and watch industries. Small and medium-sized Swiss-type lathes are used for mass part production. A new generation of ISCAR’s ISO-standard rhombic turning inserts is specifically intended for this industry sector. A variety of polished inserts enable productive machining with light cutting forces and significantly reduce friction (Fig. 1). The cutting geometry is represented by two types of chip formers intended for semi-finishing, finishing and roughing. The insert design is focused on preventing built-up edges to ensure prolonged tool life.

ISCAR has developed two new carbide grades for milling different engineering materials effectively. IC716 is intended for machining titanium alloys. It is characterised by a tough cemented carbide substrate with high resistance to thermal cracks and a new high-hardness ceramic PVD coating with a smooth surface. IC5600 is designed for cutting steel. This grade features a submicron substrate, a multi-layer MT CVD coating, and an applied post-coating treatment. This combination substantially improves the resistance of IC5600 to abrasive wear and thermal loading and enables increasing cutting speeds and MRR.

The development of machine tools has made Y-axis turning methods common. These methods facilitate extremely stable cutting and enable the evacuation of long chips in a downward direction due to gravitational force. The metalworking industry increases its demands for advanced cutting tools specially designed for Y-axis turning. One of ISCAR’s prominent new product lines is the NEO-Y-SWISS line of integral turning tools. (Fig. 2). A modular tool concept that utilises a tool assembly based on standard elements such as holders, heads, shanks, extensions and reducers is an effective way to find the optimal tool for specific applications. The distinctive feature of ISCAR’s new modular quick-change heads system NEOSWISS is comprised of diverse heads with indexable inserts for turning, grooving, parting, and threading operations on Swiss-type machines (Fig. 3). This system enables removable heads and insert replacement in the limited working space of a CNC machine.

To stay up to date on modern age machining, ISCAR accentuates rotating tools with exchangeable cutting heads such as MULTI-MASTER and CHAM-IQ-DRILL. These modular lines with the ‘No Setup Time’ phenomenon, enable quick head replacements that annul dimensional adjustment and CNC program corrections. This diminishes machine downtime and assures high machining repeatability. The modular design concept of ISCAR tool lines makes customising tool configuration easy. 

A significant functional improvement features ISCAR’s tool digital companion; 3D and 2D tool representations, tool assembly options, advanced E-Catalog and additional application software form the virtual tool environment. ISCAR’s Tool Advisor, known as NEOITA, enables searching for an optimal tool for a specific machining operation. Based on analysis and knowledge, this system generates a set of more efficient solutions with suitable cutting data, calculates MRR, and cutting power and enables direct access to the e-Catalog, insert wear detection and more. 

A new responsive design application has brought NEOITA to handheld devices. Through cloud-based technology, the NEOITA is available 24/7 and in multiple languages (Fig. 4).

A robot never dies

There are few more vocal champions of engineering and manufacturing supply chains than CNC Robotics’ Managing Director, Philippa Glover. In the second in our series on women in the frontline of advanced manufacturing, we catch up with her to talk robots, space exploration, machining, Catapults and James Bond. By John Yates

It is hard to believe that just six years ago the ebullient Philippa Glover had hit a career low. After almost two decades heading business-critical teams in global corporates – from senior R&D scientist roles through to managing operations, people, processes and strategy – in 2016 she suddenly found herself facing the threat of redundancy. 

“It was a big shock to the system,” says the mother of two Philippa who is now Managing Director of CNC Robotics, who are pioneering the use of industrial robots as an alternative to traditional machine tools. “Redundancy puts a big dent in your confidence and makes you doubt your ability.”

Reflecting on that painful period today she says: “There’s been a huge amount of growing as a result of that negative experience, which I can use to support others. It was only after having my children and going through redundancy whilst on maternity leave that I started to recognise my true potential and the role I had to play. I didn’t set out to be an MD – I set out to make a difference.”

And what a difference. For Jason Barker, who founded CNC Robotics with his wife Madina in 2010, bringing Philippa into the team is transforming the business, enabling him to focus on what he loves the most and does the best – finding integrated robotic solutions for difficult machining and large format additive manufacturing operations. 

“I don’t say it often enough, but she has been fundamental in driving the growth of the business and instrumental in the step changes that we have made. Without her we would still be in our old building, employing a handful of people with no strategic purpose. I’m a serial innovator, my passion is technology. Finding solutions is what gets me up in the morning,” says university-educated sculptor, Jason, who went from designing and building sets for stage and screen, to setting up CNC Robotics.  

It was on the set of the James Bond movie, Tomorrow Never Dies, that Jason first conceived the idea of a robotics and machining match up. “We were asked to make fake hands for a scene involving a robot, which got me thinking about how I could put a spindle on the end effector and use it to carve the parts for the sets we were making, saving us time and money.”

When he put the idea to the robot’s handler on the set, he was told quite categorically that translating the data from the CAD/CAM world to the robot world is all but impossible. That was the only spur Jason needed: the next day he was the proud owner of a robot. “The guy was right, the challenge wasn’t the robot, it was the software and the simulation,” said Jason.

Around that time, Delcam – a world leader in advanced CAD CAM for manufacturing – were exploring software for robots and looking for partners. They found one in Jason and by 2008 Delcam had developed a marketable product with Jason in prime position to become their integrator: CNC Robotics was born.

Today they are a KUKA platinum partner, with customers ranging from defence and aerospace through to building super yachts and exploring space. “Within the robot world we have a niche role in terms of our skill set and expertise. We excel at integrating robotics machining and additive and are the go to people in the UK for advanced machining applications and solutions,” says Philippa, as we tour the firm’s new factory in Liverpool where the integrated robotics solutions are designed and manufactured.

The team is busy creating solutions for a client working with in the space sector. “It’s really exciting to be working with such a talented and disruptive start-ups and it says so much about CNC Robotics that they have selected us as a partner in this project,” says Philippa of a company that is challenging Elon Musk in the race to Mars.

Like CNC Robotics, the players in the space sector sees robotics, automation and additive as key to the future of advanced manufacturing. These cutting edge ‘factories of the future’ are using the fusion of 3D printing, artificial intelligence and autonomous robotics to create an autonomous, reconfigurable production process that will create rockets from raw material to finished product within 60 days.

Back here on planet earth, Philippa says: “There is a huge opportunity for large format additive, particularly in response to the supply chain and energy crises since it supports reshoring and reducing energy costs. Take casting for example. The lead time to cast a part compared with 3D printing is significant, so you can potentially have those parts on demand. Likewise, as more firms look to light weighting there will be a shift from metals to composites where robots sit really well.”

But she also acknowledges that, despite the big productivity gains offered by robotics and automation, UK manufacturers, with the exception of automotive, have been notoriously slow at grasping that opportunity. Germany, by contrast, which is the biggest adopter of robots in Europe has three times more than Italy, five times more than France and about ten times the UK stock. 

“It’s hard to know why we are so far behind curve, but it almost feels systemic. One thing is for sure, there hasn’t been the financial backing to help manufacturers like us to research, design and build integrated robotics solutions. If we want to develop a new machine, it can be really difficult to get any support. If you want to write code, it’s happy days,” says Philippa who spent a year with Innovate UK’s Knowledge Transfer Network (KTN) before joining CNC Robotics, gaining an insider’s view of industrial policy and the public support infrastructure to help manufacturers boost productivity.  

Today, she is a vocal advocate of small and medium sized firms on a variety of industry bodies dominated by major players like Siemens, BAE Systems, Rolls-Royce, Airbus and Jaguar Land Rover. In a recent meeting with the then Industry Minister, she challenged him about the complexity and confusion in the business support network, which disadvantages smaller and medium sized firms who cannot afford to employ staff solely dedicated to securing funding. He listened, took notice and promised to follow up on her challenge. It wasn’t always so easy and with the current political turmoil it won’t be moving forward.

“I remember one of the first meetings I went to where I was a lone voice speaking up for SMEs among a group of major OEMs. It can be quite intimidating, but my views and experiences were positively embraced and led to good debate and action. I have since learnt that as long as you are authentic and speak from experience your voice will be listened to. There is growing momentum and we need to encourage and support more people from smaller companies on these advisory boards to provide a much more rounded view of the challenges and opportunities the industry face to help shape the future,” said Philippa, who has seen the world from the perspective of both the OEM and the SME.

“I hadn’t really worked with smaller firms until I joined the KTN and was confronted by all these brilliant start-ups, scale ups, and innovative smaller businesses, who needed support in quick time. My network exploded during that year as I saw first-hand what it was like to be a smaller company trying to make it to the next level,” she added. 

It was during her year with the KTN that she came across ‘the weird and wonderful creature’ that is the Catapult. At times supportive, but often difficult for SMEs to engage with.

Sitting on the Industrial Strategy Challenge Fund Made Smarter advisory board has enabled Philippa to better understand the wider, national funding landscape for manufacturing. With £147million of public money to be invested in industrial digitalisation technologies, such as robotics, artificial intelligence and additive manufacturing, Made Smarter is very close to the heart for CNC Robotics.

“I’ve asked some really challenging questions in those advisory groups and they listen and influence where they can. There are so many talented people working behind the scenes at organisations like Innovate UK who care about shaping a better future. However, as a nation it doesn’t take away from the fact that we fundamentally lack an industrial strategy that sets the vision for the future with manufacturing at its heart,” she said.

With a supportive peer network of trusted friends – northern and national business leaders who share her passion for UK manufacturing and innovation – Philippa no longer feels she is a lone voice. By cultivating a ‘growth mindset’ she understands that there are limitless possibilities not just for personal growth, but also for growth in advanced manufacturing. 

“It’s amazing the talent we have here in the UK. Business leaders who really care about their people, who are incredible innovators. We just need to create the best climate in which they can grow.”

Bridging the gap in engineering

The engineering industry has historically been, and unfortunately still is, male-dominated. Research from Engineering UK revealed that by the end of 2021, only 16.5% of those working in engineering were women, a small rise compared to 10.5% in 2010. In 2018, another Engineering UK report found that BAME women make up less than 2% of all engineering professionals.

This lack of diversity in the field is a well-known issue in the UK that the industry, education sectors, and government have been looking to address. There is still work to be done, not just in attracting more young women into following the education and working paths to engineering, but in how we nurture and develop this talent in the industry. 

We need to be more conscious of how we can support diversity in the industry and break down barriers that already exist. 

A Conscious Shift

During my time at school, I was told several times that industry was actively hiring women engineers in an attempt to ‘equalise the workforce’. To me at the time it seemed like these initiatives existed purely to tick a box, however, I have seen many of them grow to be something far more beneficial in driving equality. These initiatives have enriched the organisations that support them with a diversity of background, opportunity, and thought.

This has been no easy feat. In mainstream education, girls are interested in STEM from an early age but interest drops off as they get older. For example, in 2019 women accounted for only 19% of those studying technology and engineering degrees. STEM initiatives, targeting students from Key Stage 4 to early university, often come too late. By this time, those committed to engineering have often already overcome initial barriers on their own. We need to nurture prospective women engineers from the start of their journeys right the way through, not just when it comes to sitting state exams.

Both academic and vocational routes into engineering need consideration with a greater shift towards apprenticeships and vocational experience being a focus. In the UK, only 15% of STEM apprentices last year were women. Teams benefit from being diversified with individuals who have extensive practical knowledge.

Charities can have a major role in driving positive change for diversity, inclusion and equity in the engineering sector. Autodesk supports Girls Who Code, which works to close the gender gap in computer science and change the image of what a programmer looks like and does.

Language also has an important role to play. The terminology in job descriptions can impact a candidate’s feeling of confidence to apply. To tackle this more immediate problem, Autodesk uses the Gender Decoder, which evaluates the use of inclusive language and gender-neutral terminology in job descriptions. This has helped modify job descriptions and avoid any language pitfalls that could potentially alienate applicants.

Role Models and Mentors

The engineering industry can be an isolating environment with few peers that look like you and the imposter syndrome of being a ‘Woman in STEM’. I have felt this acutely; the fear of reinforcing negative stereotypes and thus not being able to make a mistake, playing into the idea that women do not belong in STEM. If it wasn’t for a female physics teacher at A-level, I may not have had a relatable mentor to provide a positive influence on my perception of STEM industries.

This is where role models and mentors come in. Outreach programmes are essential in raising awareness of possible career paths. Mentorships can instil confidence, empowering and enabling future women engineers, whilst allowing the mentor to fulfil her own continued professional development in nurturing future generations.

Mentorship schemes within the workplace give the freedom to discuss any issues and learn from more senior women who’ve had the same experiences. For me, it provided a support network of women, with whom I could have an open conversation, allowing me to realise some barriers I thought I faced were internal or no longer so prevalent. This builds on the huge efforts made, primarily by women, to tackle the issues we face in STEM.

Fostering Belonging in the Workplace 

Organisations must look to building a culture of belonging, where all employees have equitable opportunities to succeed and contribute. 

In 2020, Autodesk launched a new global diversity strategy that focuses on individual, interpersonal, and structural dimensions of change and transformation. One of the key objectives is to increase the representation of women in tech, including increasing gender diversity in engineering.  

At Autodesk, we have several programmes to foster a sense of belonging in the workplace. For example, the Autodesk Women’s Network is one the largest employee resource networks in the organisation, consisting of over 1,600 members across 40 offices globally. Despite sometimes still being the only woman in the room, being part of this community has given me a platform to share my experiences and learn from others. It’s a community where peers can help each other develop and realise their full potential. 

Hybrid working also holds the potential to improve the situation. We know that women face a disproportionate burden in terms of childcare and other unpaid work. This new model helps all employees to strike a better work-life balance, giving them the flexibility to work around personal and family commitments both from home and the office as needed.

New horizons: Greater Access 

Ultimately, companies across the industry need to ensure they are actively considering how they are bridging the gender gap. This must involve participation in outreach programmes, proactively supporting women from the early stages of education, commitment to apprenticeship programmes, and then recruiting these women post-formal education. These programmes should also be attuned to the specific barriers that further marginalised women face including BAME women and LGBTQ women. 

As an industry, we’ve made a huge amount of progress already and as the sector grows, expanding infrastructure and support provisions will instil confidence and empower all. 

Engineering is a fantastic area to be a part of, with a mixture of hands-on and digital experience to be gained. There is nothing like conceptualising a design and then seeing it come to life.

By focusing on internal support and external outreach, we will widen routes into engineering careers. In the years to come, I hope to see even more women engineers working in STEM, to the point where it is no longer noteworthy.

PEMBREE designs path to success with Fusion 360

Throughout his school days, Phil Law always had a passion for cycling, this passion led the creative teenager to design bikes and ramps for GCSE and A-level subjects. As part of a product design degree at university, Phil won an award from the Audi Design Foundation for the design of his magnetic pedals for cyclists with knee injuries. Subsequently, the fundamentals of the degree failed to help the enthused designer grasp the gravity of turning the design concept into the reality of manufactured parts – but it did introduce him to Autodesk. 

As a graduate with no ‘hands-on’ manufacturing experience, Phil Law had all the enthusiasm and dreams but not a route from drawing board to realisation. Not perturbed by his inexperience, Phil spent a few years in various manufacturing businesses in different roles to understand the manufacturing process. Prior to PEMBREE Ltd being founded, Phil had subscribed to a ‘non-commercial’ license of Autodesk Fusion 360, which enabled the prospective business owner to develop his pedal designs without incurring excessive costs that would clip the wings of any new business. 

When the company did actually open its doors, just six days before the pandemic-induced lockdown in March 2020 – the start-up business took delivery of a HAAS VM3 machining centre, measuring equipment from Mitutoyo, a SIC laser marking system, a deburring machine and a commercial suite of Fusion 360. The company has progressed rapidly and recently added a robot-loaded Brother 5-axis CNC machining centre.

All about sustainability 

When asked what finally gave the budding entrepreneur the push to start the business, Phil says: “I always wanted to start a business that would challenge the sustainability of the bike industry, but it was a discussion with a cyclist at a holiday resort that was the true catalyst. The cyclist told me he goes through 3 pairs of pedals every year – typifying the consumable ‘throw-away’ culture we live in. This is largely down to the approach that most companies take – just looking for the next sale. At PEMBREE, we are taking a holistic view of our products. We look at the product design, how we manufacture the product, its service, use and ultimately how it can be recycled. The challenge for a lot of companies is that they use materials that are not recyclable. Sustainability by its very nature is something that you can continuously repeat, and too many manufacturers claim to be sustainable by just paying a carbon offsetting fee. Everything we do is sustainable – even our factory is powered entirely by solar and wind power.” 

The Autodesk Journey

Looking at where the Autodesk journey started, Phil says: “I started using Fusion 360 prior to starting PEMBREE. What I loved about it was that it enabled me to conceptualise some of the ideas I had, create 3D models and even 3D print parts to see if the components could be manufactured, would fit together and ultimately work as an assembly. Fusion 360 was instrumental in the start of the business and it has ultimately grown with PEMBREE; helping our business to become what it is today. The high-value CAD/CAM solution has enabled me to launch the company forward at a greater speed. As we have manufactured more complex parts, we have adopted the Fusion 360 Machining Extension.”

“For our latest product, a stem, the Fusion 360 Machining Extension has enabled us to optimise our processes through features like Part Alignment. This has been hugely important in reducing the potential for scrap. It has enabled us to load parts into the machine and align them correctly via a feedback loop whereby our measuring probe is used to capture the shape and positioning of parts and send data back into the CAM system. From here, Fusion 360 will re-align the pre-defined machining strategy with the position of the part. This eliminates errors and scrap when we conduct the first operation, but more critically when we move from the first to the second operation and conduct secondary part clamping. The Part Alignment strategy guarantees that we are not miss-aligning and subsequently scrapping parts.” 

“From an alignment perspective, we could never be 100% accurate when re-setting the parts for second-ops – especially complex forms like stems. So, using the part alignment feature within the Machining Extension ensures that the second operation is entirely accurate. A huge benefit is that we have saved a fortune by not having to buy bespoke fixturing, as we can now make our fixtures in-house. We have also reduced potential scrappage costs and saved time by not having to meticulously set the parts on the machine.” 

“With the on-machine probing that checks the pedals in-situ with Fusion 360, we have saved more than £5000 by not having to buy bespoke fixturing. We knew the Part Alignment feature would save us a lot of time, effort and money in getting this new stem design to market. In fact, we developed this new stem and the production process around the Part Alignment strategy. This has enabled us to bring the new product line to market much faster than we would have done otherwise. Even for simple 3-axis parts, we use the Part Alignment strategy to probe the part and compensate for any setup errors, meaning we can maintain a high level of precision.”

The Horam based business in East Sussex initially launched its first pedal, the R1V in August 2020. This was followed by the launch of the D2A pedal. Both models have a range of design variants and the small business manufactures hundreds of pedals each month from aerospace-grade aluminium alloy. The high-quality pedals were machined on a HAAS VM3 with a Chick 4th axis rotary unit that has standardised clamping on each of the four faces of the horizontal tombstone. With the arrival of the robot-loaded Brother Speedio, PEMBREE is now moving the pedals to the automated 5-axis machine whilst the HAAS VM3 has been fitted with a HAAS 5th axis rotary unit for 3+2 machining of the new stem. 

Creating the Swarf

Moving the new stem from a concept to reality has been a seamless process with Fusion 360. “We designed the stem with Fusion 360 and transitioned from design to CAM model with absolute ease. With the Machining Extension, we have applied strategies like Part Alignment, but we have also taken advantage of the Swarf machining strategy. This 5-axis machining strategy uses the side of the cutting tool to machine geometry both accurately and efficiently. For example, we have proven-out the stem with a ball nose end mill as this would be perceived as the tool of choice for an intricate 5-axis part. However, with the help of the Swarf machining cycle, we have determined that using the side of a standard end mill is not only faster, but also improves the surface finishes. In the case of the stem, this strategy has taken a 5 minute profiling cycle down to just 30 seconds and it has improved the aesthetics of the part and eliminated any potential secondary hand finishing.”  

“We started using the base version of Fusion 360 but decided to invest in the Machining Extension to access some of the more advanced capabilities for our CNC machines. The 5-axis swarf tool path has played a major role in launching the new stem. It enabled us to produce a beautiful chamfer, a design feature that’s key to the overall aethetic and something I know our customers are going to love. The swarf machining works an absolute treat.”

Looking to the future…

The small company can be proud of its achievements since its inception. PEMBREE takes immense pride in not only being one of the few UK manufacturers of bicycle components but also exporting its products worldwide through an established network of distributors. The company has also signed up brand ambassadors like biking legends Rob Warner, Tomas Lemoine and Daryl Brown. 

Another point of beaming pride for the micro-manufacturer is its environmental credentials. “All of our products are designed with sustainability in mind and are 100% carbon balanced with TEMWA, this goes beyond design, manufacture and sourcing our materials, but also our consumables and packaging through to delivery. Also, in accordance with our environmental values, our pedals are 99.9% recyclable and everything we do at PEMBREE is carbon neutral.”

And with Autodesk..

The next step in the Fusion 360 journey for PEMBREE is the implementation of the FEA (Finite Element Analysis) within Fusion 360. Alluding to this, Phil adds: “We design a lot of concept bike parts and having the FEA capabilities will allow us to prove out the mechanical properties of our designs. There are a number of critical components on a bike and if they fail, it could be very dangerous for the rider. At present, we design and produce 5-6 different pedals and then send them to Germany for intensive analysis and testing. If we implement the FEA functionality in Fusion 360, we can identify, trial and prove out the properties of different materials and design concepts and how they would perform in ‘real-world’ conditions. This will reduce our prototype production costs and it will provide more design freedom, as we will be able to visualise and analyse designs with full consideration for the stresses and loads that will be placed upon the parts.”

The company is also implementing the Autodesk Prodsmart suite, a Manufacturing Execution System (MES). This exciting technology will optimise the shop floor at PEMBREE by connecting the entire business through digitised and automated manufacturing processes. With the facility to enable PEMBREE to conduct job planning, assignment, management, tracking and analysis throughout the production process, this software solution incorporates a real-time data dashboard, workflow visualisation and performance tracking and effective scheduling and inventory management. With the facility to increase efficiency, reduce waste and eliminate paper processing, the Autodesk Prodsmart suite is likely to yield significant savings for PEMBREE. 

To learn more about PEMBREE, visit 

https://pembree.com 

To learn more about Fusion 360, visit 

https://www.autodesk.com/products/fusion-360 

To learn more about the Fusion 360 Machining Extension, visit https://www.autodesk.com/products/fusion-360/machining-extension

Gear maker measures gains

In almost every corner of its 35,000sq/ft factory, there is evidence of Ondrives commitment to delivering the best products it possibly can to its customers. From high-end CNC machining centres to state-of-the-art offline tool setting technology, its Chesterfield headquarters has got the lot. Like any successful company, Ondrives’ positive reputation precedes it – that is why it has invested in a VICIVISION system from the Carfulan Group. 

Established in 1995, but with origins dating back more than 80 years, Ondrives has designed and made more gears and gearboxes than it’s possible to remember. The bespoke product range covers everything from spur and helical gears to gear splines, worm wheels, spiral bevel and hypoid gears. The company supplies market segments such as aerospace, motorsport and bespoke general OEM engineering machines – in fact, any industry where precision is a prerequisite.

Ondrives Chairman Ben Hinchliffe said: “People don’t just want something that’s a standard shape or form. They want exactly what they want for their machine to make it the most efficient or the best, and we’re able to do that fairly easily because we invest in the equipment to allow us to do it. When you walk around Ondrives and see the machinery, software, equipment and people, it’s a modern facility. When somebody buys a one-off, hundred-off or thousand-off, they’re going to want the very best equipment in the world for making that product.”

Mr Hinchliffe certainly classes VICIVISION in that ‘best equipment in the world’ bracket. Ondrives uses an M309, an optical metrology machine catering specifically for turned, ground and cylindrical parts. “We manufacture for the aerospace and motorsport industries that need tightly controlled components,” said Mr Hinchliffe.

“We started looking at expanding our measurement capability and went down for a demonstration at VICIVISION, took some parts and was impressed with what it was able to produce. We want to be able to measure run-outs, chamfers and corner radii, and to do that in a format that allows us to have printable and saved PDF reports. We’re looking for detail and accuracy and the VICIVISION is a perfect product for that.”
Using a combination of advanced video camera technology and light projection, VICIVISION’s Techno range automatically delivers fast, detailed and consistent results independent of the operator. Even the most complex part features can be inspected in seconds, down to the last detail. Mr Hinchliffe added: “The actual accuracy of the machine when it is producing measurements is great. In fact, it’s got a nice couple of features on it where it will go and calibrate itself before it starts a process of measuring.”

“We have parts where we’ll measure some radii, lengths and diameters which will then be processed for gear cutting and then when they get onto precision grinding, they return to the VICIVISION and are then measured for a tolerance that’s +/-2.5 microns. If you’re producing a big quantity and you’re getting the reports to back that up for customers it’s excellent. It means the blanks can meet that quality and exceed it, and you can’t ask for more than that.”

Thanks to their wide measuring fields, impressive load capacities, high-resolution capabilities and intuitive software, VICIVISION Techno systems meet both current and future manufacturing demands by guaranteeing speed, efficiency and precision in all measurement tasks. The improvements they bring to quality control processes can contribute to a significant reduction in rejects and rework, immediately increasing throughput and positively impacting profitability.

“For optical scanning, a machine like the VICIVISION is a must in our industry. You need this type of equipment to verify the component you are making,” said Mr Hinchliffe. “You can scan it instantaneously. If it’s a component that takes 60 seconds to scan on a VICIVISION, it might be a 20-minute job on a CMM. So, if you’re doing 400 components, and you want to inspect one out of 10 or even every one, this is the type of machine you’ve got to use. Once we’d had the demonstration with the VICIVISION and saw the report layout it was able to produce and the accuracy of the products, it sold itself.”

“It’s worth the extra investment to buy a machine like this and also spend time with the right people to learn how to use it, because when you do, the benefits you get are immeasurable. It can measure, but the benefits will be immeasurable to you as a company.”

Based at its state-of-the-art Innovation Centre in Derbyshire, VICIVISION UK has a team of vastly experienced engineers with a thorough knowledge of the full hardware and software range. By offering installation, calibration, fixturing solutions, programme creation, applications support and bespoke training, the company’s turnkey packages make for smooth project set-ups so that customers will start reaping the advantages of optical measurement from day one.

Mr Hinchliffe concludes: “The VICIVISION has improved quality all the way along the process chain. You’ve got to invest in measurement machines to get the most out of the product you’re going to make. Nowadays, if you want to be in the industry that we are in – a first-class, quality product company – you have to be able to invest in this type of technology.”

Start-up business invests in ITC tooling for success

Founded at the height of the pandemic in September 2020, AXI5 Ltd is a subcontract company that manufactures high-end bespoke components for the motorsport, oil, gas and press tool industries as well as designing and producing specialist tooling and toolholders. The company set itself up for success from the start with the purchase of a Mazak Integrex i-100 5-axis multi-tasking mill/turn centre, a Hurco VM10i machining centre, hyperMILL CAM software from OPEN MIND Technologies and cutting tools from Tamworth specialists Industrial Tooling Corporation (ITC). 

Immediately investing in the latest CNC machine tool technology, a high-end CAM system and industry-leading cutting tools from ITC, the Southam-based company has made a phenomenal start in its first two years of business. Like any business, the support of supply chain partners can be instrumental to success, and AXI5 has recognised this on numerous occasions where ITC has supported the fledgling business with everything from ITC Widia VariMill end mills, general purpose Widia Hanita end mills, the Widia VDS drills and ITC’s extensive range of threadmills. When the small business was having challenges machining a series of high end components, it was ITC’s Application Engineer Simon Yeomans that was on hand to support the company.

With demand for regular batches of 50 to 100-off parts for a prominent company, AXI5 was having issues with its cutting tool performance. With the project expected to be an ongoing regular commitment from the customer – a solution was needed. So, AXI5 called upon ITC to solve the problem. On its compact Hurco VMC, the Warwickshire manufacturer set up two Microloc clamping systems to machine 100mm diameter billets that are 92mm long. The set-up was clamping on 15mm of stock with a bar protrusion of 77mm. 

Despite the robust performance of the Microloc system, rough machining a square profile in the round billets created excessive noise and didn’t give the AXI5 team the confidence to leave the machine to run through its cycle. As well as creating excessive noise, the 25mm diameter indexable end mill was also providing limited tool life and poor material removal rates. Investigating the process, ITC’s Simon Yeomans recommended the Widia VXF high-feed 52mm diameter face mill with five insert seats for the rough machining of the parts. 

With two parts clamped on the machine and milled in a single operation, the previous cycle time with a rival tool was 15 minutes, something that ITC rapidly cut to just under nine minutes – a 40% cycle time-saving. This was achieved by executing cutting parameters of 163m/min with 0.75fz and 0.8ap with a ramp angle of 0.7°. The result was that the 15-5PH stainless steel parts that had been annealed to BM9050 and were proving a particular challenge, one that had been overcome by ITC with a significant productivity increase. 

The key challenge for AXI5 was having the confidence to walk away from a process that was creating excessive noise. Thankfully, the smooth cutting action of the Widia VXF high-feed face mill eliminated excessive noise and chatter and gave the small business confidence to allow the machine to run unattended. The impressive cutting characteristics of the ITC Widia VXF tool also delivered reduced costs and prolonged tool life. 

With two parts clamped in the work envelope simultaneously, AXI5 could only machine four parts before an insert change was required with the previous tool. However, the ITC Widia VXF could machine three batches of parts as opposed to two – 6 parts instead of 4. This impressive performance on a particularly difficult material equated to one hour of machining time for each insert edge with the Widia VXF face mill. Equally impressive is the ability of the new ITC Widia tool to reduce costs for the business. On a run of just 600 parts, ITC is expected to save AXI5 over £4000 – or £6.60 per part. 

As a company utilising the latest machine tool technology to machine a wide range of materials that stretches from steel and stainless to titanium and nickel and chromium-based superalloys – the journey with ITC is just getting started and the cost savings and productivity improvements will continue to follow.

Discussing the relationship with ITC, Production Director and Co-owner Dave Wear says: “We have known the ITC team from previous roles with other businesses and their support and products have always been outstanding. So, when we set up our own business, ITC was one of the first companies we called. They are a UK manufacturer, which means they hold stock of thousands of items and provide next-day delivery. This is not often the case with overseas manufacturers. The pricing structure is clear and concise and we also utilise the re-grind service. As a small business in the early stages of growth, having a re-grind service to minimise our costs and waste is of critical importance to us. Our next step will be to have a consignment stock of ITC products.”

“The product quality is second to none and we have improved tool life and cycle times over and again with the Widia range from ITC. The ITC threadmills that are manufactured in the UK are also giving us 3-times tool life improvements when compared to previous products. We have outstanding support, friendly advice, an unfathomably wide choice of products, industry-leading performance and the majority of tools are manufactured in the UK – what more could a manufacturer want from its cutting tool supplier. Our next move will be to organise a consignment stock for our ITC tools,” concludes Dave.

Performance boost with NeoMill face milling cutter

The family-owned company BOGE Kompressoren with its headquarters in Bielefeld, Germany, is a world-renowned leader in units for generating compressed air. Apart from the performance, quality and cost-effectiveness of the products, one of the most important declared goals is the increase of efficiency and safety in the manufacturing process. When producing screw compressors, MAPAL‘s high-performance tools achieve convincing results.

“We at BOGE are the centre of competence in supplying readily assembled and inspected compressor stages for screw compressors,” explains Mario Birkner, Production Manager for Organisation and Projects at the BOGE plant in Großenhain. The progressive company manufactures mechanical components for screw compressors. In Großenhain, around 40 employees produce very accurately machined rotors and housings in highly automated machining centres. During assembly, they are turned into functionally tested mechanical units, which are then delivered to the main plant in order to be completed with drives as well as measuring and control technology. During manufacturing, the focus is on optimum cost-effectiveness. The manufacturing costs for new products are already defined to a large extent during the design stage, in line with the global market standard. Therefore, the corresponding department is located in close proximity to the production. The developers can thus easily communicate with the production specialists. This helps designing products which are immediately ready for production and on time.

From design to optimised processes

“After development, I take care of coordinating the machining operations for the components, so that we can achieve stable, safely controllable and cost-optimised processes,” explains Kevin Schmidt, responsible for project handling of prototypes in production. The cast-iron rotors and housings are machined separately, each on a highly automated production line or island. For new products, the tools and machining parameters suitable for optimal results need to be determined first. Further essential aspects are other general conditions, such as runtime limits or the expenses for maintaining or changing the tools. In addition, there is the design and production of suitable clamping devices and fixtures as well as the definition of test equipment, test fixtures and test plans to ensure the desired high level of quality. Finally, the plant also has test stations for examining the behaviour of units under real-life conditions.

The long-standing development partnership with MAPAL

“There are many critical machining processes for housings,such as position bores or the bearing areas in rotors,” knows MAPAL’s application engineer Heiko Süss. Often, strict IT6 or IT7 precision requirements have to be met. This is where fine boring tools from MAPAL, designed exactly for these tasks, come into play. Not only is maximum precision important here, but  machining times must also be as short as possible. Well-designed multi-stage tools often result in low material removal rates that are sufficient to carry out several machining steps. Moreover, the custom tools achieve considerably closer tolerances and better surface qualities while maintaining the same high process reliability. In this area, BOGE and MAPAL have had a close partnership in development cooperation for a long time.

In the early phase of new projects, Heiko Süss already receives an inquiry from BOGE regarding the tool concept to be used for optimal machining of the new components. The machining solution suggested by MAPAL is then elaborated on within the team and validated in tests.

Proving to be effective for milling cutters with indexable inserts

“In our discussions, other questions always arise in addition to the actual topic of conversation,” says Kevin Schmidt. One of these conversations with Heiko Süss was about the unsatisfactory performance of the previously used face milling cutters from a market competitor for roughing thrust bearing caps. These milling cutters were fitted with indexable inserts and had a diameter of 160 mm. However, their machining performance in roughing was insufficient, so that two or sometimes even three cuts were necessary in order to remove the required material thickness. Süss made Schmidt aware of the new NeoMill face milling cutters with radial indexable inserts and recommended a NeoMill-16-Face face milling cutter with a diameter of 125 mm for this task. The tool is fitted with ten indexable inserts, each of them with eight cutting edges on both applicable sides and was used in production for tests lasting several weeks.

A sweeping success

“With these new tools, we were able to achieve really impressive success,” Mario Birkner is pleased to say. The material removal rate, increased from two to four millimetres, already made it possible to reduce the required machining time by half. Furthermore, it was possible to double the feed due to the softer cut and thus lower power consumption of the machine, so that the machining time decreased by more than 60 percent.

The tool life per cutting edge of the indexable inserts resulted in further time and cost advantages: 60 instead of the previous 45 minutes. In addition, the costs per cutting edge were reduced as well. This is because the octagonal (ONKU) indexable inserts from MAPAL’s NeoMill range, which are now being used, have a negative basic shape, can therefore be put in on both sides and have 16 cutting edges each in total. Thus, full replacement of the insert set is only necessary after 16 hours of use instead of the previous six hours, with corresponding positive effects on expenses for changing tools as well as on handling costs. In direct comparison with the previously used milling cutter, 45 machining hours can be saved when machining 1,200 parts.

However, these advantages could only be used to their full potential within the framework of a machine software optimisation: previously, an adaptive feed regulation automatically reduced the feed rates specified by the NC programme according to certain parameters. This automatic system proved to be too slow for the rapid machining of the NeoMill milling cutter. MAPAL’s face milling cutter was only able to realise its full performance potential after this function was deactivated. According to Mario Birkner, MAPAL will also be contacted for further machining processes in future projects.

Five questions to ask when machining threads

By Christa Kettlewell and Jamie Rosenberger of Allied Machine and Engineering

There are many elements to consider when threading a workpiece. When is a solid carbide thread mill better than an indexable? How does the workpiece material behaviour impact thread milling? Understanding your program as well as diagnosing issues that arise are just as important. Luckily, thread milling can be better understood by asking five specific questions.

When would you want to thread mill instead of tap?
There are many instances where you would want to consider using a thread mill instead of a tap. In numerous cases, this comes back to one common issue: taps break. Because the tap is the same size as the hole, there is a lot of pressure when you are forcing the threads into the hole – even more so in difficult-to-machine materials. Additionally, a tap’s cutting edges are constantly in the cut, thus generating more heat. A thread mill on the other hand has little contact with the material, and the heat generated is much lower – an added benefit in any manufacturing process. Finally, when using a tap, chips are more difficult to form and remove.
All of these things mentioned above lend themselves to tool failure. When the tap breaks off, it often results in a scrapped part, so using a tap works better when it is an inexpensive part being made. If it is a more expensive part and the tap breaks, you are now faced with the challenge of trying to remove the tap and salvage your part. This is a time-consuming operation that impacts your part quality and manufacturing cost.

Not only would you want to thread mill whenever the part is expensive, but you would also want to thread mill when working with a large hole diameter. Of course, a tap is just as large as the hole, so for a four-inch thread diameter, you need a four-inch diameter tap. Instead of buying this expensive, large piece of metal or storing taps for every thread size, you could buy an off-the-shelf thread mill and interpolate the thread into multiple thread sizes including those large diameters. Lastly, thread mills consume significantly less power from your machine in the instance of large diameters.

Other advantages of thread mills include the ability to hold tight tolerances by controlling the tool’s cutting path. As the tool shrinks slightly from wear, you can easily compensate for this at the machine by using tool diameter offsets.

Nevertheless, there are occasions where tapping may be the better choice over thread milling. For example, you would want to use a tap when machining long lengths of thread. Due to the lack of radial load, there is no concern about the tap’s stability or tool deflection. In addition, when speed is preferred over thread quality, taps are again the better choice. In many applications, a tap will have a shorter cycle time than a thread mill. However, this still comes with the risk of breaking the tap and spending your valuable time to get it removed.

When should you use solid carbide thread mills vs. indexable thread mills?
In choosing to use a thread mill, you have the option of solid carbide or indexable thread mills for your application. This choice often comes down to the needs of the application in terms of quality, repeatability and flexibility.

Solid carbide thread mills
Quality and performance are key advantages of solid carbide thread mills. Solid carbide thread mills run and cut faster every time. Having constant surface footage between two different diameters will result in a different RPM. Due to their smaller cutter diameter, solid carbide thread mills will run at a higher RPM. In combination with typically having more flutes, this will result in a faster penetration rate (in/min or mm/min) and improved cycle time. These tools typically outperform indexable thread mills in terms of quality because threads are being ground at the same time. This improves the consistency of threads. With a smaller cutter diameter, there is less contact with the workpiece, resulting in less heat generation and deflection as well.

Indexable thread mills
Most users are attracted to indexable thread mills because they provide the ability to change thread forms frequently. You can take one body and change out inserts, and the machine is up and running with different forms or pitches rather quickly. Ultimately, this makes indexable thread mills better for low production batches as well as job shop type of work with a lot of change over and variation in the manufacturing. This again comes back to the flexibility of the tooling. You have a one-time purchase of the body and then switch over the inserts as needed.
All in all, a thread mill is simply milling a thread form and a pitch and can usually be used for both left and right-hand threads, internal or external, multiple start threads and various tolerances.

How does the material impact a thread milling application?
Material removal in threading is no different to any other manufacturing process like boring or turning. There are always two things to consider:

• How much material is being removed?
• What is the material like to machine?

The first question can be answered by the thread pitch. While a fine pitch does not require much material to be removed, a course pitch requires a lot of material to be removed. The combination of these two questions will also help you determine whether your material can be removed in one pass or not. Regardless of how many passes you use to remove the material, just like with boring or turning, a finish pass can be used for improved quality. This is often referred to as a spring pass. If needed, you should refer to the technical section of your manufacturer’s catalogue or an available thread mill programming software like InstaCode to choose the number of passes that are right for you.’

What are the best practices for programming?
As mentioned above, a thread mill can create a variety of threads like left or right-hand, internal or external by simply manipulating the program/tool path. Writing a program in incremental movements instead of absolute is always preferred. In doing so, you can insert your code for the threading portion as a sub-program or sub-routine. This is beneficial when threading multiple holes because it provides a single place for program edits. This also allows you to quickly complete a test run above the part to prove-out the program. In addition to writing this in incremental movements, an arc-on and arc-off movement will improve the quality of the thread and extend the life of the thread mill.

How should you diagnose issues when thread milling?
Because thread mills have radial cutting forces, deflection should always be kept in mind. Factors mentioned previously like how much material you are removing and what the material is like to machine can be approached by adjusting the number of passes to remove the material as well as the combination of speed and feed. Additionally, consider the tool holder you are using. Because of the radial forces and potential deflection, it is necessary to use tool holders such as milling chucks, hydraulic chucks or shrink fits that minimise deflection. Ultimately, these tooling solutions are more rigid and, therefore, improve the quality of the thread you are machining.

It is also necessary to understand if the programmed tool path is based off the centre of the thread mill or the outer diameter of the thread mill. This changes how wear offsets should be applied in the machine.

CBN insert proves decisive at Hydropower specialist

With a 169 year history, Gilbert Gilkes & Gordon (Gilkes) designs and manufactures hydropower turbines and pumps, exporting to over 85 countries. The company supplies pumps to the marine, rail and automotive sectors and hydropower turbine systems installed as far afield as Alaska and Australia. 

Created in 1853 to manufacture agricultural equipment, under the name of Williamson Brothers, the company’s first order for a turbine was registered in 1865. It was in 1881 that Dublin-born businessman Gilbert Gilkes purchased the company and a prestigious customer at that time, Lord Armstrong, installed a water turbine at his home, Cragside, the first house to have electric lighting.

Many of its products harness the natural power of water flowing in rivers, described as run of river systems. “Wear has always been an issue given the application, so we are constantly looking at new, more exotic materials, to help reduce wear and to extend operating time. Most recently we have utilised tungsten carbide coatings on the runner systems within our turbines. This posed challenges to our in-house production team who worked closely with Ceratizit to achieve the desired result,” says Derek Thomas, Gilkes’ Production Engineering Manager.
The part in question was a 600mm diameter F35 Super Duplex ring that was subject to abrasion from sediment. To overcome this, Gilkes added a Tungsten Carbide coating, the application of which caused out of roundness, which then had to be machined away. The challenge was how to remove this excess material. Matthew Darbyshire from Ceratizit suggested a new insert grade that would allow us to turn the part on the Mazak.”

The insert was a brand new CBN grade CTBH 40U, which had been developed for turning hardened materials where the intermittent cutting was an issue. Two inserts with cutting data of 210m/min surface speed and 0.12mm/rev feed rate with a 0.25mm depth of cut were suggested by Matt for testing. “The result was superb, just one insert was needed to complete the machining operation and the surface finish was excellent. The insert cut the tungsten carbide coating like a dream,” says Production Engineer Justine Marshall.

In the case of Gilkes, Matt visits on a fortnightly basis to discuss any upcoming requirements as well as servicing the two Ceratizit tool vending machines on-site. One of these vendors is the latest TOM 840 unit capable of storing up to 840 individual items with monitoring and reordering done remotely by Ceratizit, this unit is used to stock regular consumable cutting tools, such as inserts and drills. While the second vendor is an older TOM 60 system, which Gilkes maintains for tooling such as special taps and regrinds. The use of this older system, with its glass front, is due to the preference of Gilkes’ operators who want to physically see stock levels of these lesser used, but vital tools.

“The support we give to the team at Gilkes is what we would provide to any customer. The vending solution covers the vast majority of their day-to-day needs, and my regular visits take care of everything else,” says Matthew Darbyshire, Technical Sales Engineer, Ceratizit UK & Ireland. “We have worked together for over 16 years now. This ensures that things run smoothly. In addition to new tools, we also take care of regrinds of Ceratizit products, collecting them every month to be returned to the factory to be refreshed to original condition. We also provide a recycling service for used carbide inserts. These are collected every quarter and their value is returned to Gilkes in the form of a rebate on new products.”

Advances in aluminium machining are supporting the shift to EVs

According to the International Transport Forum, transport activity is expected to double by 2050 compared to 2015 levels. With climate change concerns, we must produce more efficient vehicles. Eduardo Debone, Senior Manager for Automotive Offer Management at Sandvik Coromant, explores how material innovations are supporting the transition to more environmentally-friendly vehicles. 

While Covid reduced transport activity, vehicle use is still set to rise as population increases and economic development continues. Producing more vehicles is inevitable — the real challenge is making them greener. The International Energy Agency (IEA) reports that transport already accounts for 24% of direct CO2 emissions from fuel combustion, with road vehicles accounting for nearly 75% of this figure.

The United Nations Framework Convention on Climate Change (UNFCCC) recognises the importance of lowering emissions, and has released its Climate Action Pathway for transport earlier in 2021. The UNFCCC’s vision is that, by 2050, passenger and freight transport will be decarbonised following a shift to more sustainable technologies.

The EV evolution
Among zero-emission transport is EVs, which executive director at the IEA, Fatih Birol, says “have a role to play in reaching net-zero emissions worldwide”. By using electricity, from sustainable sources, EVs produce zero tailpipe emissions and are thus more environmentally friendly than ICE vehicles.

According to the 2021 report, there were ten million EVs on the world’s roads at the end of 2020, and EV registrations increased by 41% that year. While EVs are clearly on the rise, their adoption can be accelerated further by overcoming range anxiety. The range is not just down to the battery. In addition to better charging infrastructure and improvements to EV battery design, EVs needs to be made lighter. An EV with a lower weight requires less energy and can therefore go further on a single charge.
Aluminium plays a role in light-weighting EVs. Aluminium is now selected for vehicle parts such as the chassis, internal panels, motor housing and battery enclosures. According to the Aluminium Transport Group (ATG), using aluminium to reduce an EV’s weight can result in range gains of proportion. If the vehicle weight is reduced by 20%, it should be able to travel 20% further on the same charge.

Mastering machining
However, aluminium is difficult to machine as it is softer than most metals. What’s more, the melting point of stainless steel is 1510 degrees C, for aluminium it’s 660. The lower melting temperature means that chips can build up at high speeds and adhere to the tool. This accumulation can dull the tool, making it difficult to cut. In addition, issues such as tool setups, inconsistent tool wear, burr formation and inferior surface finishes occur.

These challenges can be overcome by selecting an optimised tool like the Sandvik Coromant M5C90 face milling tool. Part of its M5 cutter series, was designed for aluminium milling, as well as roughing and finishing cylinder heads, blocks and EV parts. The M5C90 can perform the entire process from roughing to finishing with a DoC of up to 4mm, increasing tool life fivefold and reducing cycle time by up to 200%.

In addition, the M5 cutter series features step technology, where its extremely hardwearing PCD inserts are arranged in a spiral and staggered vertically to remove material from the workpiece both axially and radially. Other tools in the M5 series include the M5B90 face milling cutter concept for fine finishing and the M5F90 combination milling cutter for roughing and finishing in smaller dimensions.

The transition to EVs will lower transport emissions, and adoption can be accelerated by increasing their efficiency. EVs that take advantage of aluminium components can travel further per charge, helping to overcome range anxiety. Automotive manufacturers who select machining tools optimised for aluminium will be able to produce high-quality aluminium EV components – helping to support the shift to greener travel.

How to increase parting off and grooving productivity

Parting off and grooving are demanding turning operations. Many parameters determine the result. In addition to the rigidity of the machine, feed rate and cutting speed, the parting-off and grooving tool are decisive factors governing the quality and efficiency of the operation. If you ignore the diversity of materials, blades and holders, it will quickly become very costly. 

With parting off – the devil is in the detail. There is so much to be considered in this turning operation. After all, it plays a decisive role at the end of the turning process – after the added value has already been invested in the workpiece. In addition to feed rate and cutting speed, groove width and cutting depth, chip evacuation is one of the factors that requires particular attention.

Diversity reflects application experience
Anyone who underestimates the complexity of grooving and only uses individual parameters for their decisions will pay dearly. This also applies to parting-off and profile grooving. Suppliers with application experience, consultancy expertise and fast-response service can boost processes and productivity by upwards of 400%.
Family-owned Arno offers parting-off and grooving systems with a diversity that reflects the company’s vast experience. The double-edged SA grooving system with groove widths of 1.5 to 10mm is suitable for cutting depths of up to 140mm diameter. Together with many modules, holders and blades, the parting-off tool is always optimally adapted to the situation. Arno offers a wide range of machine-related flange-mounted holders for many machine brands.

Stability and low vibrations
Users can choose from six geometries, seven coatings and two solid carbide substrates to achieve the best possible results. The SA grooving system is adapted to steel, stainless steel, aluminium or difficult to machine materials. It ensures an uninterrupted cut for applications that require optimum chip-breaking geometry.

Chips tend to build up and jam in the groove, especially at parting-off. This is compensated for by using the right geometry. It also produces high-quality parting-off surfaces, as the system works with low vibration due to its high stability, regardless of the feed rate and cutting speed.

For grooving applications and Swiss-type machining, the manufacturer recommends the flexible solution of its SE groove turning system. As it is highly stable, it achieves perfect results despite high lateral forces. The SE system allows users to part off, even if workpieces have a large radius. This is shown by groove widths of 2 to 6mm and cutting depths of 12 to 21mm. Other features include its easy handling and long service life. Here, too, seven geometries demonstrate the manufacturer’s broad experience with materials and requirements. Users can also order precision-ground inserts for SA and SE systems with an aluminium geometry, or sintered inserts with geometries suited to many materials.

Arno has developed a third tool for small diameters. The three-edged ATS system can be used by turning operators for a wide range of short, precise grooves. ATS offers a large cutting depth of 6.5mm. Groove widths start at a very narrow 0.8mm and extend to 6mm. When it comes to profile grooving inserts, contours up to 20mm long can be mirrored on one insert.

Think about the processes, not just the products
Some tool manufacturers will also find custom and application solutions to improve processes and increase productivity. Here, Arno presents products that demonstrate precisely this philosophy – such as its AWL/AFC quick-change tooling system. The two-part carrier tools make for quick tool changes that even unskilled personnel can easily perform safely.

To hold effectively

Toolholders were designed for mounting cutting tools reliably. They also facilitate the torque transmission from a machine spindle to a rotating tool. It has been a long time since we have encountered significant changes in toolholding, which may suggest we are behind in innovation. Indeed, well-established tool clamping principles, the need for wide interchangeability and unification and standardised designs of machine tool adaptations have resulted in well-defined standards, which specify detailed toolholder parameters. But this doesn’t mean that new innovations and developments are over.

Time puts new demands on machining, which has transformed into new requirements for machine tools, and consequently, cutting tools and toolholders – both elements of a chain that enables the recognition of machine tool capabilities possible when machining a part or a surface. The toolholder relates to the most ‘conservative’ link of the chain and has undergone fewer revolutionary changes for the noted reasons.
The Industry 4.0 philosophy has had a serious impact on toolholding. Smart manufacturing and the demands of tomorrow’s manufacturing is requiring intelligent toolholders to exchange data via Internet of Things (IoT) platforms. This will lead to new information capabilities of toolholders by adding more and more electronic units. Even today, built-in chips provide various data regarding a toolholder that communicates with machine tools, industrial robots, storage devices and more.
Adding a new data function is no doubt an extremely important direction in the evolution of toolholding development. However, it does not negate the need to continually improve mechanical design, which may look a little bit prosy when compared to the enthusiastic data intelligence of smart tooling. However, it should be noted that a traditional development that relates to the advancement of toolholders as mechanical systems, is very far from coming to an end.

Recent improvements in toolholder designs are distinctly seen in the following areas:
1. Heat-shrink chucks
High-speed machining (HSM) methods have brought tool balancing requirements to new heights. In HSM, the dynamic characteristics of a tool cannot be separated from a toolholder, and a particular focus must be given to the assembly on the tool and the toolholder. Hence, minimising the unbalance of such an assembly is one of the challenges tool developers face. They have tried to guarantee the required balance parameters at the design stage before production. This engineered balance design cannot replace ‘physical’ balancing of an assembly, but it substantially diminishes the mass unbalance of a future product and makes ‘physical’ balancing much easier. Axisymmetric heat-shrink chucks optimally meet the requirements of a balanced toolholder for HSM already in the design stage. This explains why the advance of heat-shrink chucks is of priority.

2. Coolant supply
A pinpointed coolant supply through a tool body, such as when coolant flow is directed to a cutting zone significantly improves machining performance. The industry requires more advanced toolholders with internal supply options, especially for machining with high pressure coolant (HPC).

3. Modular quick-change tooling
A modular design principle considerably simplifies finding the optimal configuration of a tool assembly and diminishes requests for special tools.

4. Long-reach applications
Long-reach machining applications inherently require the long overhang of a tool assembly, which leads to poor stability that increases vibration. New solutions with improved assembly strength are just one of the trends of toolholder development in this area.

5. Polygonal taper connection
The ISO-standardised polygonal taper adaptation has proven itself and become common in multitasking machines and turning centres.
These are only a few of the high-profile directions for developing toolholders. The others are focused on high-torque transmission to prevent tool pull-out because of the high axial cutting forces. Other innovations evolve around increasing accuracy and creating more ergonomic solutions. Therefore, the conclusion of a seemingly stagnation in the mechanical design of toolholders is far from correct.
By use of example, let’s consider the newest toolholding releases from ISCAR over the past few years.

Recently, ISCAR expanded its family of heat-shrink holders by adding new chucks with C8 polygon taper shank. The chucks offer several bore sizes from 6 to 32mm. The introduced products feature coolant channels along the chuck bore to provide effective coolant supply to the cutting edge of a clamped tool.

Due to increasing popularity of the polygon taper adaptation, ISCAR has developed a new tool family for external and internal turning and threading applications. A modular concept enables various tool assemblies using a wide range of cutting heads with indexable inserts. These are mounted on toolholders with polygon taper shanks with a serration-face connection.

What else can be seen as new in ER spring collets? Tool manufacturers have developed a rich variety of precise collets that offer coolant supply capability. For example, ISCAR’s new updated ER rubber sealed collets with an extremely narrow collapse range ensure better clamping force, maintain high runout accuracy of 0.005mm and facilitate four cooling jets.

ISCAR’s integral collets, tools with a tapered shank for direct mounting in ER chucks are accurate and rigid tools. These are considered as toolholders in their own right. The front of the collet has its own adaptation for mounting cutting heads with indexable inserts or they are fully made from cemented carbides.

Hydraulic chucks ensure high gripping torque that is vital for heavy-duty machining. During recent years, ISCAR extended its product range of hydraulic chucks, they are now available with BT-MAS, DIN 69871 and HSK shanks. In addition to a high-torque transmission and fast tool-change capabilities, the hydraulic chucks are characterised by excellent vibration damping properties and high accuracy.
ISCAR developed a system of quick-change assembled tools specifically for turning aluminium wheels. A tool assembly comprises of a cutting head and a holder. The head is mounted on the holder by use of a dovetail connection. The dovetail mechanism assures full-face contact between the holder and the head with very high clamping forces and this enables it to resist tough cutting conditions when turning wheels. The holders are produced with VDI40, VDI50 or round shanks.

We can see that progress in toolholding is far from exhausting the resources of advanced design. Although high-quality toolholders have reached the right level of performance to meet the needs of today’s manufacturing challenges, the smart factory of tomorrow demands an even higher level. Intelligent design in combination with progressive technology, continues to play a key role in toolholding improvement.

A thread of success

In the highly competitive cutting tool industry, the majority of manufacturers offer a comprehensive range of quality solutions without necessarily being outright experts in one specific field. There are obviously some exceptions to the rule, but they are few and far between. As world leaders in threading, Vargus is one of the few and far between. Vargus has a 60 year pedigree in the niche arena of threading, so MTD Magazine spoke with Ori Ehrenberg, the Medical Industry Product Manager and Baruch Books, the Vice President for Sales, Marketing and R&D. 

One of the first subject matters that was broached was the new MACH threading line that was launched back in January. The MACH Supersonic Threading range for Thread Turning and Thread Milling applications is a completely new innovation. Explaining the MACH line, Baruch Books says: “The MACH range was three years in development. As innovators, we lead and not follow, we are only competing against ourselves. The MACH series is a completely new method of generating a thread. We started from the ground up with new toolholder designs, insert geometries, coatings, substrates and so on. We didn’t want to improve on an existing product line. Our target was to improve cycle times by 70% and we achieved this. In the process, we have also massively improved tool life and surface finish. For instance, a thread that typically takes 10 to 12 passes can now be finished in three passes, and see dramatic improvements in tool life and surface finish!”

This example highlights how Vargus differentiates itself from other cutting tool manufacturers. In fact, in the last three years, the company has introduced more than 25 different product ranges. Baruch credits the investment in R&D: “We restructured our business model and have invested heavily in R&D in the last three years. We have doubled the number of engineers we employ, and we have invested significantly in machinery and other technology. R&D and engineering now account for 20% of our employee headcount, as an investment in people is the key to success. Our technical centre has six machine tools running 24/7, trialling and testing new tool developments, creating hundreds of kilos of swarf daily.”

Medical Excellence
With life expectancy extending through medical advances, the industry is a significant growth market for manufacturers of everything from prosthetics and implants to surgical equipment. Commenting upon this, Ori Ehrenberg says: “Average life expectancy has risen from 60 years in 1950 to over 80 years in Europe and North America. We are becoming more dependent upon implants and joint replacements as we live longer. As technology advances, there is a greater demand for more complex products and this creates more opportunities for manufacturers. However, like the automotive industry, the medical industry and its supply chain are looking for lower cost per part, shorter lead times and to reduce manufacturing costs without compromising quality.”

Adding to this, Baruch states: “This industry is going through rapid changes with the onset of technology like 3D printing of organs, valves and complex geometry prosthetics. Added to this, some countries have witnessed exponential population growth and this brings further demand for technological revolution. We have always strived to reduce production costs through new technological advances. What we are doing at Vargus is working with leading innovators in the medical industry, such as the academics, surgeons and researchers to provide solutions for the future demands of the sector.”

Expanding upon this point, Ori says: “There is a strong move towards implants now being 3D printed in different types of materials, especially in titanium, stainless steel and even composite materials. This, however, does not diminish the demand for threading applications since all implants require a screw connection.

“We have excellent standard solutions for stainless steel and titanium applications, which are extremely popular in this industry. And we are now working with a host of medical R&D facilities on how to create threads in composite materials without witnessing the common issues of delamination and poor thread quality. This is an exciting challenge that we are fully embracing. Every material has a different story and composition with the fundamental common attribute that it is very difficult to machine. We are developing threading tools with new edge preparation techniques to prevent delamination and also new methods of applying tool coatings to the substrate to prolong tool life and performance. Like everything at Vargus, this is a relentless pursuit of improvement that will never end.”

“Almost every implant requires a thread to attach it to the bone and the surgeon conducting the procedure has a multitude of standardised thread profiles to choose from. Whilst many cutting tool manufacturers try to be full-line suppliers, the unique applications demand extremely technical solutions and Vargus is one of the very few cutting tool manufacturers that can accommodate this. Not only are we the biggest threading tool manufacturer in the world, but we are also breaking boundaries with our R&D. Whilst the technological evolution of the medical industry exponentially expands, we are already advancing technologies with the leading medical companies and research facilities for the next generation of advancements,” adds Ori.

Looking at some of the challenges faced by the industry, Baruch says: “Every industry faces the same challenges of increasing operational and material costs as well as the pressure to deliver more bespoke products at shorter lead times with reduced cost-per-part requirements from customers. We recognise these concerns and we have created solutions based on the issues that manufacturers face. For example, we worked with machine tool manufacturers to introduce our thread whirling system to increase productivity and reduce costs and set-up times drastically – incorporating features like multiple start threads. With regard to additional applications such as groove-turn, front and back turning, and parting off, we addressed the issue of material cost and worked to strengthen and enhance our solutions. For example, for parting off tools such as our ST-Cut and VG-Cut, in our GROOVEX – Grooving and Turning Line – we lowered the parting off width dramatically. Our parting inserts offering once started at 3mm width and have decreased to 2mm, then 1mm and now as low as 0.5mm. Where we have differed from other manufacturers is that we have retained the performance, productivity, strength and tool life of our tools. This may seem a small incremental move, but saving over 2mm of waste from each part manufactured from a bar can have a huge impact over a week, a month or a year – saving the customer thousands in material costs.”

“In addition, we have a wide range of internal micro-machining solutions in our micrOscope Line, specifically designed for the medical and dental industries. We are now able to machine inside holes less than one millimetre in diameter.”

Looking to the future, Baruch concludes: “I believe we are the most interesting company with the most diverse and innovative solutions for industry. We create the technology ourselves and always develop unique product lines. Our heavy investment in R&D will help us to continue at a rapid pace. It is easy to copy somebody else’s methods and follow in somebody else’s footsteps, but at Vargus, we are committed to leading the industry, not following. This is how we break new boundaries and stay ahead.”

Automating auto assembly

It was the demise of a subcontracting business with ongoing projects that led two engineers to step in and complete the outstanding projects. Seven years later Gary Hill and Stewart Shelton have built success with DForce Engineering Ltd, completing a string of prestigious projects for clients in the automotive industry. 

The Leicester business has evolved to a team of 12 with an 11,000sq/ft facility. It was the kudos of completing three major (50+ robot) installation projects for Toyota across Europe that have contributed to the growth of the company. Over the last five years, DForce has counted the Sertec Group, a worldwide automotive supplier as a key client. The relationship has evolved from jig and fixture design to manufacturing, planning and software design – to full system supply. For the latest project, DForce incorporated the robotic expertise of FANUC UK. 

The brief was to design two complete automation cells for the self-pierce riveting (SPR) and self-pierce studding (SPS) of aluminium underbody components for delivery as four complete sub-assemblies to a UK automotive production line. In each cell is a FANUC robot, a preferred choice of DForce and Sertec.

With the arrival of a new vehicle concept, Sertec required two separate automation cells for the vehicle underbody. Commenting, DForce Director Gary Hill says: “FANUC is the preferred brand of Sertec. As part of our design concept, we proposed to further utilise the larger of the cells with the addition of RH & LH Self Pierce Studded assembly parts thereby running three different assemblies through one cell by using a FANUC R2000iC robot – cutting the cost, floor area and cycle times by delivering two cells instead of three.”

The first cell has two manual loading and unloading stations, each working with a FANUC R2000iC robot. On one side, two assembly stations are fixing both two and three components together, a process that requires Self Pierce rivets of two different lengths and studs. The robot, an R2000iC/210F has a 210kg Stanley Tucker dual-feed rivet gun attached and it identifies the correct part and rivets. “We needed the capacity of the FANUC R2000iC/210F robot, as the rivet gun is very heavy. The R2000iC/210F robot has to maintain both a positional and repeatability accuracy of +/-0.1mm. The kinematics and precision are outstanding as the R2000iC/210F moves the rivet gun with repeatability 24 hours a day.”

Whilst this process is being undertaken, the second station is loaded with parts that are collected by the second robot, an R2000iC/165F which also picks the first completed assembly using a double-sided gripper and transfers it to a TOX pressing machine for Self Pierce Studs to be inserted. Discussing this, Gary says: “The cell has an output of over 80,000 parts per annum with a 96 second cycle time for the three assemblies. All three assemblies require studs or Self Pierce Rivets of varying lengths. To compare this to manual studding, the process used to take 8 seconds per stud and then you have to add non-productive time for loading, unloading and part re-positioning. With the new cell, the operator can spend 20 seconds loading the station and then move to another task. This is a massive saving.”

The second cell incorporates a manual load and unload station for two-part variants and the FANUC M-20iA/35M robot that transfers the assemblies from the manual load & TOX pressing station to the dual feed TOX pressing station. Alluding to this cell, Gary says: “The FANUC M-20iA/35M robot is compact with a small footprint and it has a maximum payload of 35kg. This suits this assembly as the gripper is 28kg and the assembly weighs just 2kg.”

This robot has a repeatability of +/-0.03mm and will identify the different hole positions and rivet sizes and press the 10 rivets through the holes. Discussing the timeline, Gary adds: “The design of the two cells was an 8-week process, we then spent another 16 weeks manufacturing the cell. The FANUC ROBOGUIDE system compressed this time. This robot simulation suite enabled us to simulate both the robot’s motion and application commands.”

The FANUC ROBOGUIDE system reduces 3D modelling times and enables part models and assemblies to be imported from a PC as CAD data. Designed to be intuitive and extremely easy to use, ROBOGUIDE requires very little training. 

In conclusion, Gary says: “FANUC has been outstanding throughout the process. The robots have delivered everything we have required with precision, speed and repeatability and the FANUC ROBOGUIDE has compressed the timescale of the project immensely.”

1st MTA cuts the chains of manual working

F B Chain is an industry-leading manufacturer of Leaf Chains, which are a particular type of chain for materials handling applications, forklifts and telehandlers. Producing complete systems that are ready to fit on forklifts or in production lines, FB Chain also produces chain kits, sheer face blocks, connecting links, chain anchor pates and complete assemblies. To speed up production the company has invested in Halter robotic loading systems from 1st MTA. 

Commenting upon how the Letchworth company previously manufactured its products before the arrival of Doosan machining centres with Halter automation, Managing Director of FB Chain, Mr Peter Church says: “We used to have some old Bridgeport machines and a bank of single index units with up to 8 indexers on each machine. We would then have an operator who would stand next to the machine to load the parts into the machine, press the start button and then unload the finish components – a very manual process.”

The 5-year plan

The company had a five-year plan to double the turnover of the company, alluding to this, Peter adds: “In 2011, we came up with a vision for the future that included doubling our turnover. That vision drove what we were doing and made us concentrate on our output and how many parts we were doing, what storage we needed and even what sort of building we needed. It soon became apparent that if we were going to double our turnover, we had to double the number of components that we produce. We started by looking at things like additional shifts and extra machines, but at that point, we realised that running two shifts was going to be almost impossible. That started us thinking about how we could automate our processes.”

Looking at the solution, Peter comments: “We had these eight indexing units and we wanted to know if we could automate and teach a robot how to load the index units rather than using a person. So, we looked around at solutions for robots, but it was very expensive. We continued our research and came across Halter, and their technology looked like a plug and play system. It appeared relatively simple and we had some conversations with them and the price was more realistic. We flew over to Germany to see one working in 2014 and we pretty much bought it on the spot. Now, we have six systems and we are just ordering the seventh.”

The integration of automation into the shop floor enabled the manufacturer to hit its vision of doubling turnover. As Peter continues: “in the first five years of implementing our plan to double turnover we achieved our goal. Then we went and doubled our turnover again. The requirement for our equipment comes from our ability to provide a solution. We provide the chain and the parts in a complete kit that is ready to use. Some of our kits may contain 70 or 80 components and if a customer was managing this process, they would require a lot of resources. This means that over the years, more and more companies have become interested in our solution, which is the complete chain kit.”

Looking closer at the automation solution, the Halter system is delivered with a selection of component grids. “When we bought our first machine there was only a fixed number of grids that came with the machine, but we did some work with Halter and we customised the grids and increased the capacity further. We started with just 68 parts on a grid and now we have some with 209 component grids on a machine, twice.” Alluding to the unmanned running potential, Peter says: “We have a job here that is running at 2 to 3 minutes per part and it automatically loads the second part whilst unloading the first and it will run for 18 to 19 hours a day. It has been a game-changer.”

Moving from a manual machine shop to an automated facility, Peter says: “I think you have to change the way you think, but the Halter system is very easy and if you have a very basic understanding, within 10 or 20 minutes you can be programming the robot. If you tell the system a particular set of parameters such as the diameter and length of the part you are loading and the diameter and length of the part coming out of the machine – the robot does it all for you.”

Considering the staff, Peter concludes: “I don’t think anybody embraces change initially but a lot of our staff saw the boring element of the job, which was the loading and unloading of the machine just disappear. This allowed employees to move onto tasks like programming and process engineering, so in the end, it has all been very well received.”

Machining to within one-third of a micron

In the production of optical components such as lenses and mirrors, the specified form accuracy and surface roughness are generally an order of magnitude higher than for other machining processes. That is why Son-x GmbH in Aachen, Germany, a spin-off from the famous local Fraunhofer Institute, uses a 5-axis machining centre built by Roeders. The manufacturer’s machines are available in the UK through sole agent Hurco Europe, High Wycombe.

Son-x manufactures parts from various alloys, including high-strength steels, as well as parts made of clear plastic. Quantities range from single pieces to several hundred per year, while dimensions extend from a few millimetres up to half a metre diameter. Sectors that use the components produced include optics, laser, sensor, astronomy and research. Additionally, moulds are machined for producing lighting systems used in the automotive industry.

Dr.-Ing. Olaf Dambon, a director of Son-x advised: “Our early work involved ultra-high-precision diamond turning, but parts started coming along that needed a prismatic machining platform able to achieve similar accuracies. We drew up a specification sheet for the machine we wanted and designed a challenging test part for prospective suppliers to produce. Five machining centre manufacturers were shortlisted, including three from Japan, but we chose the Roeders because its trial machining results were the best.”

An order was therefore placed for a Roeders RXP 601 DSH 5-axis machining centre. Dr.-Ing. Benjamin Bulla, another director of Son-x commented: “Given our high precision requirements, machine rigidity, smooth running and thermal stability were priorities. The Roeders machine appears rather large at first glance for the size of work we undertake.”

He explained that milling complex optical arrays with hundreds of tiny cavities for lenses sometimes takes more than 50 hours. Throughout this time, the machine reference point must remain extremely stable to ensure the exact alignment of each lens. The RXP 601 DSH achieves this due to its linear direct drives, high-precision linear guideways with frictionless weight compensation in the Z-axis, and high accuracy optical scales. 

With its Racecut functionality, the Roeders control system compares the actual and target positions in all axes 32,000 times every second, compensating for even the most minimal path deviations as they occur. Exceptional thermal stability is provided by a medium, temperature controlled to ± 0.02°C, circulating through all important components of the machine. The temperature of the production environment is also kept stable by an air conditioning system.

The machine is equipped with a Levicron air-bearing spindle capable of rotational speeds up to 60,000rpm. Thanks to its smooth running and good damping characteristics, it ensures the production of top-quality surfaces in all materials. 

“In one instance we had to mill moulds for arrays of hundreds of plastic lenses whose shape had to be controlled to within 316 nanometres. This tolerance was reliably maintained throughout 50 hours of machining, even for the last lens in the array. We are highly satisfied with the results.”

Potty over Colchester investment

Strata Products is a leading UK manufacturer of home, office and garden plastic products. With over 200 employees working in a 320,000sq/ft facility, Strata Products operates its 35 injection moulding, blow moulding or rotationally moulding machines 24/7. To make sure the injection mould tools remain in perfect operational condition and to keep the production lines running, the company has invested in milling and turning technology from Colchester Machine Tools.

Based in Nottinghamshire, the company has won numerous awards from its blue-chip customer base and also recognised industry bodies. The company produces over 15 million units every year that are supplied to more than 40 countries around the world, processing over 13,000 tons of raw material in the process. 

Looking at the toolroom that ensures the injection mould machines can run around the clock, Ben Hyder, the Engineering Manager at Strata Products says: “We make a wide range of plastic products and we have a wide range of plastic injection mould tooling that we have to keep in ‘tip-top’ condition, as some of these tools run 24 hours a day, seven days a week – for weeks on end. The tools have to maintain their accuracy and keep an excellent running order. Once the tool has completed its production run, it comes into the tool room. Sometimes the tool will only need a basic clean and service and a check over, but other times there will be problems associated with the running conditions. This will be general wear and tear or some damage that may have occurred.”

“A typical example of a problem would be an ejector pin that may have scored up and caused the injection mechanism to seize and the tool not to open and close correctly. An example of this was a reamed hole that we recently had to open up from 6 to 6.5mm on the milling machine that we bought from Colchester. I also have a plant pot injection mould tool where the pins that make the holes in the bottom of the plant part became flattened and damaged. This meant we had to make new pins that are made on the Colchester Triumph VS lathe. We have also had two broken nozzles from the barrel of a machine that secretes the plastic into the back of the injection mould tool – again, these have been re-made on the Colchester Triumph lathe. The machines are very useful at enabling our business to keep on top of any issues we have with our tooling.”

The Colchester Triumph VS lathe has a 400mm swing over the bed, 1200mm between centres and a 54mm spindle bore that makes the machine suitable for a wide range of components. With a 7.5kW spindle motor, the machine can achieve spindle speeds of 14 to 2500rpm. 

Looking at the daily operations on the Colchester machines, Ben adds: “We manufacture lots of spare parts such as nozzles and other standard spare parts, as we like to keep a supply of spare components that we can just interchange in the tools. With the job being different every day, the Colchester machines are very user friendly and the features on the machine are very ergonomically placed for ease of operation.” Looking specifically at the Colchester Student Plus semi-CNC lathe, Ben adds: “It’s not a full CNC machine but it has around eight basic functions that you would use. It is also very easy to programme where you would have several basic dimensions to input and it writes the programme for you automatically. This means that you don’t have to learn any programming language or G-Code. We are very pleased with the Colchester machines and their ease of use – this suits the nature of our environment perfectly.”

Astec reaches for the Stars

Established in 1998 as a manufacturer of miniature precision, turned and milled screw machine parts from 0.2mm to 32mm diameter for high specification industries, Astec Precision recently wanted to embark upon machining larger components. With a range of sliding head turning centres from Star already installed, including a bank of SR-10J Type C machines, the Cumbrian company opted for another Star machine, this time the choice was the Star SX-38 Type-A.

Discussing the acquisition, Managing Director, Mr Eddie Young says: “At Astec Precision, we currently machine micro components and micro turned parts for the aerospace, medical, interconnect, energy and offshore sectors. There was a demand for us to make larger and more complicated components and this was the reason to bring the Star SX-38 Type A with HFT technology into our business.”

“The Star SX-38 gives us a bigger machine capacity, as before our largest machine was 32mm capacity. This machine gives us a 42mm diameter capacity and it allows us to machine longer parts that are more complex. It is also a more flexible machine than what we had before.”

Taking a closer look at the machine and the process of understanding how to operate the new Star SX-38 Type A, Julie Emma-Fell from the Ulverston based company says: “It was a steep learning curve as this machine has three paths, but programming the new machine is certainly not an issue now.” Explaining the three paths, Emma continues: “On the head one, we have the tool platten with some driven tools and on head two you have the back turning tools for the sub-spindle and thirdly, there is the lower tooling turret that has multiple stations that can use driven tools, turning tools and drills on it.”

Commenting on what the robust new turning centre can accomplish in comparison to its predecessors, Emma says: “This machine gives us more flexibility on head two for machining on the sub-spindle – previously we wouldn’t be doing much more than drilling on head two. This machine has really opened our eyes to what we can do on head two. With the twin spindle and three tool turrets, there isn’t much that this machine cannot do. As a business, we are trying to get into machining more shell bodies and larger capacity parts. At present, we are machining larger and more complex parts out of materials like inconel and monel. One of the jobs on the machine is a prototype part for a customer that is being machined from monel – it has an 85mm deep hole drilled in it, and this would have been impossible to do on any of our other machines – especially as there are a lot of tolerances tied to +/-0.01 to +/-0.02mm.”

“Overall, I have thoroughly enjoyed learning how to use the Star SX-38 Type A machine. We have also had some interesting periods when we are using tooling turrets one and three at the same time for roughing and finishing and the tools are quite close together. The flexibility and productivity of this machine make it a great turning centre – I absolutely love using it,” concludes Emma.

JSG tools up with another Sodick EDM

A Hampshire toolmaker has added to its portfolio of Sodick machines with a new AL40G die-sink from Sodi-Tech EDM. JSG Engineering is enjoying long-term success using a range of Sodick EDM wire, die-sink and hole-drill machines that provide high-quality work and generate repeat business.

Specialising in all aspects of mould tool manufacture, JSG Engineering has built a strong reputation for customer satisfaction. Established in 1990, the family business manufactures all types of mould tools, including plastic and rubber injection, rubber compression and transfer tools at its 4000 ft² facility near Portsmouth.

“Business is strong at present, particularly on the pharmaceutical side,” states Director Gary Carpenter. “One customer has been requesting several mould tools as we’ve progressed through the Covid-19 pandemic.” 

This demand recently led the company to review its die-sinking capacity. JSG Engineering had some older die-sink machines on site that were reaching the end of their service life. 

“We’ve been buying Sodick machines for the past 25 years and currently have a number on site,” says Mr Carpenter. “These machines, which include AQ325L, A530D, AQ45L and K1C models, have been very reliable for us, so it made sense to look at Sodick again. There’s nothing else out there that touches these machines in my opinion.”

During a telephone conversation with Sodi-Tech EDM, JSG Engineering learnt that a demonstration model of the Sodick AL40G die-sink model would be on display at MACH 2022, so Mr Carpenter expressed his interest. It was not long before the machine was undergoing installation at the company’s Emsworth facility. The AL40G die-sink EDM incorporates Sodick’s latest SP controller with Smart Pulse generator. Featuring linear motors and absolute linear scales in the X, Y and Z axes, the machine comes with a 10-year guarantee on positioning accuracy.

At JSG Engineering, the Sodick AL40G sparks tools from materials that include everything from aluminium and P20 steel to fully hardened tool steel. A notable job involves the production of mould tool inserts made from tool steel that produce plastic pharmaceutical clamps for use in drug production processes. Due to the complexity of the clamps, several manufacturing processes are required, including EDM and grinding.

“Some of the tools we produce are up to three times faster to produce on our AL40G than our previous die-sink resource,” says Mr Carpenter. “The quality is far better and we can achieve a mirror finish if required. Where before we would have to polish a cavity after sparking, now there’s no need on 90% of our jobs, it’s saved a lot of time.” 

Energy efficiency is another benefit, particularly in the current inflationary environment for electricity, where manufacturers are having to find ways of offsetting the cost burden.

Says Mr Carpenter: “The latest Sodick technology is energy-efficient and so fast with its linear technology and that means we save on our bills.”

A further plus point for JSG Engineering is the inherent ease of use that comes with Sodick EDM machines.

“We’ve had a lot of experience with Sodick machines and always found them easy to learn, even with the evolution of controls over the years,” explains Mr Carpenter. “The training package is excellent. My youngest son was at Sodi-Tech recently for some training. When he came back he knew things that even I didn’t know. Anything that helps to alleviate the skills shortage is welcome, particularly in the toolmaking sector. Good toolmakers are very hard to come by.”

JSG Engineering has its finger on the pulse when it comes to combatting market challenges such as rising energy costs and the skills shortage, thanks in some ways to its ongoing preference for Sodick EDM machines. This strategy has also led to ongoing repeat business from the many industries that the company serves, which aside from medical/pharmaceutical include defence, aerospace, nuclear, electronics, construction, automotive and marine.

HAAS Porsches the envelope at EB

As a division of EB Equipment that was founded over 60 years ago, EB Motorsport has a level of experience in advanced engineering and manufacturing in the classic motorsport sector that is difficult to match. Located on a 4-hectare site in Barnsley, EB Motorsport has an operation that covers over 6000m² with dedicated areas for shell preparation/fabrication, composite production, paint/body shop, assembly, part warehousing and of course CNC machining, which is where the company has invested in machine tools from HAAS.

With the latest manufacturing technology, EB Motorsport specialises in products and services from the supply of individual components to full restorations and bespoke builds. Giving an overview of the business, Mark Bates from EB Motorsport says: “We specialise mainly in classic Porsche 911’s and it’s a business that was born out of a hobby. For example, we have a 1965 Porsche that is going through a bare-metal restoration where literally every nut and bolt on the car has evolved with a lot of subtle tweaks. As we don’t want to annoy the purists, we have kept the main silhouette of the car without undertaking any drastic changes. Some of the changes may be a custom wire loom to details and fittings on the engine and even all the interior has been remanufactured with modern control gear.”

The company can pretty much manufacture anything with its HAAS UMC750 5-axis machining centre, HAAS ST10Y 4th axis turning centre and its 3D printing technology. “We are in an industry where this is a hobby, so when people have a component, it not only has to perform better it has to look right. We do everything from fastener production right up to the machining of the cylinder heads. We have developed the 5-axis port geometries for machining cylinder heads, the valve seats and even the valve guides.”

Looking at the investment in machine tools from HAAS, Mark says: “We have some endurance callipers for the Porsche 917’s and this was the calliper that made us invest in the HAAS UMC750 5-axis machining centre.” The callipers for the Martini Porsche car are manufactured from a range of materials with titanium fixtures that are machined on the HAAS ST10Y. It is the combination of the two machines that allows EB Motorsport to make these brake callipers. If these brakes fail, somebody could be in a lot of trouble, so the company makes seismic efforts to ensure the brakes are pressure tested and 100% correct for the customer. 

Looking at the shop floor with a range of new and old machines, Mark continues: “The business started over 60 years ago, so we have kept a lot of our machines like some of our old presses – but we have also invested heavily in things like a 4-axis Bystronic Xpert 150 press, injection moulding machines, extrusion machines and more. With the HAAS ST10Y, we went for the Y-axis variant because, in our early days, some of the staff said we would have more flexibility if we had a turning centre and a mill. The problem with that is that you would have to remove components and reposition them, which would create an issue of misalignment. The HAAS ST10Y eradicates this as we can turn and mill and it has been a fantastic machine. We have really pushed this machine, to the point where we have fourth axis CAM software to program the machine off-line – as some of the parts we produce would be a big challenge for somebody to program at the machine.”

When it came to investing in machine tools, the company wanted to grow with HAAS and this is one reason why the HAAS UMC750 5-axis machining centre followed. “I have no reason to look elsewhere. From the quality of the components we are producing, the machines we are using are several years old and even if we do have an issue – the team at HAAS have been great. We have pushed the UMC750 to its limits and we have cut everything on the machine from aircraft-grade aluminium and magnesium through to variations of stainless steel. We have even put billets on the table that are so big, we have had to lock out the table and run it as a 3-axis machine, we really do challenge the limits of the machine.”

E-mobility gearboxes are no grind with ETG

Gearboxes used in electric vehicles are not only designed for high speed and torque – but they are also very compact. This is also true for innovative applications such as e-bikes. These high power electrically driven gearboxes inspire design engineers to come up with more creative solutions. With gear manufacturing technology manufactured by Kapp Niles, the Engineering Technology Group (ETG) offers innovations for producing EV and e-bike gearboxes.

In many cases, gearboxes comprise small components with interfering contours that pose production challenges. For hard finishing of the gear teeth, the process-related potential goes hand in hand with high production costs. The most economical option is generating grinding. However, not all machines are suitable for the compact components. Here, the experts at ETG outline the demands and solutions.

Transmission manufacturing challenges include the high power density and the compact installation space in which the entire powertrain must be accommodated. At the same time, new applications are opening up new sales opportunities, such as e-bikes.

This benefits the manufacturers and their suppliers – gearbox manufacturers among them. However, be it two or four wheels, the drive technology is sophisticated. The focus is on the required flank load capacities and the noise behaviour of the gear teeth due to the boundary conditions imposed by the electric drive motor, an almost constant high torque over the speed range of 0 to 18,000rpm. However, new challenges go beyond machined parts and also directly affect the manufacturing process. Due to the compact design, an increasing number of components with interfering contours emerge in the gearbox design. Large tools with standard dimensions of the worm grinding wheel quickly and literally meet their limits.

Identify and overcome boundaries

Up to now, the finishing of gears with interfering contours has been accomplished by discontinuous profile grinding or honing. Compared to continuous generating grinding, both processes feature different disadvantages in terms of productivity, economic efficiency or quality consistency. The problem is that common grinding worms measuring 300mm diameter are too large to handle components with interfering contours.

At the same time, smaller tools require higher cutting speeds. However, previous machine concepts were not designed for the high dynamic requirements regarding tool and workpiece driving. New types of high-speed spindles in combination with a dynamic direct drive of the workpiece axis offer a solution. This enables manufacturers to exploit the advantages provided by generating grinding – a process that features shorter machining times, lower tool costs and quality consistency.

The right machines 

Through ETG, Kapp Niles offers two machine types, both equipped with high-efficiency drives for tools (25,000rpm) and the workpieces (5,000rpm). The KNG350 flex HS has a conventional design featuring one workpiece drive. The machine is available in two versions, one for miniature and small lot sizes. For higher volumes, an automated version is available with an integrated ring loader. Workpieces up to 350mm in diameter can be processed using this machine.

The machine features short set-up times that are possible through the use of intelligent components ergonomics. For large-scale production, it is worth looking at machines pre-set by design. The KX TWIN series with two workpiece drives and a loading and unloading process that is performed in parallel to the actual grinding operation offers further potential for the reduction of non-productive times.

Arturn makes a turn for Dugard

Arturn Precision Engineering Ltd has just invested in a Hanwha XD38II sliding head turning centre from Dugard to enhance capacity and throughput at its Rugby-based facility. As a Tier 1 automotive supplier, Arturn is no stranger to high-volume production runs – this is where the Hanwha machine is making a difference.

When asked why the company opted for the Hanwha XD38II sliding head turning centre from Dugard, Myles Rudkin from Arturn Engineering Ltd said: “One of the main reasons we bought this machine is because we can turn up to 38mm diameter on a sliding head machine, which in my opinion is pretty impressive, especially when the sweet spot is from 32 to 38mm – that’s where we have a broad diameter of parts, so it means we can expand the range of components that we can machine for our customers.”

Looking at the attributes of the machine that has recently been installed at the Warwickshire subcontract business, Myles adds: “It’s a great machine and where the tools are located, particularly the power tools – this makes it easily accessible to interchange cutting tools and speed-up our setup processes.”

Considering the FANUC 32i-Model B CNC control system and the programming of the machine, Myles says: “I like the programming on this machine too. It has broadened my knowledge of programming, and this is because a lot of the M-Codes are familiar, like on a fixed head machine. This means that my knowledge of fixed head machines and the respective G and M-codes will transfer directly to the Hanwha machine. So, when I come on to the Hanwha machine, it has both a familiarity whilst broadening my knowledge.”

With flood coolant on the new Hanwha XD38II turning centre, ISO: 9001-2015 accredited Arturn has noticed a marked improvement in tool life. Referring to this, Myles adds: “The coolant flow on this machine is excellent and there is a high number of coolant hoses on the machine that can be moved and directed at specific tools. This helps prolong the tool life and reduce wear, which is reducing our machining costs. We also have an LNS Mist Extraction system on the machine and this eliminates the mist from the work envelope before we open the door. So, when we open the machine door, no mist escapes and we are not breathing in the coolant oil mist and there is no oily residue in the wider machine shop.”

With the machine supplied as a complete package by Dugard, Arturn also received an LNS Alpha 342 barfeeding system with the machine. Alluding to this, Myles adds: “The LNS user interface is very friendly. It is just a case of loading the bar, pressing two buttons and the bar passes straight through the machine. It also tells you exactly how many bars you have left and how many components you have left to produce – during machining. We do a lot of mid to high-volume work from 500 to 50,000+ off and this helps. It is good to know whilst I’m running a job, how much bar is remaining. As an operator, I know exactly when I will need to get more bar and how much I will need to keep the machine running. This also helps with scheduling.”

Looking at the 26 tooling positions on the machine that allows for a maximum tool shank of 16 by 16mm with a 6,000rpm cross slide that generates 2.2kW of spindle power, Myles continues: “We do a full variety of work on the new Hanwha and this can vary from EN18 materials through to mild steel, 316 stainless and more – the machine has an excellent level of power. With one particular component that requires a large bore and two flats milled on the OD, the Hanwha has taken out two operations. This means the job can go straight out to the customer as a finished part from the Hanwha XD38II machine. The machine also keeps tolerances really well – to within a thou all the way throughout a long production run.”

Concluding on the machine, Myles adds: “What this machine does really well is hold very tight tolerances whilst the excellent coolant flow is extending our tool life considerably. Looking at the 26 tool stations, these are all very well positioned and easily accessible.”

Mentioning the impressive X1 and X2 axis stroke of 80 and 395mm respectively and also the Y-axis travel of 422mm and the Z1 and Z2 axis travel of 320 and 280mm, Myles adds: “I also really like the stroke in head 1. The long-stroke enables me to turn component lengths well over 300mm – this broadens the scope of what we can machine, as some sliding heads will only machine up to 180 to 200mm in bar length. It means we can turn particularly long shafts up to 380mm long with no problem on the Hanwha XD38II.”

Autocraft revs-up with Heller installations

When Autocraft Solutions Group (www.autocraftsg.com), Europe’s largest independent engine builder and remanufacturer, purchased the land and assets of an existing but redundant machine shop in Booth Drive, Wellingborough, in June 2018, the company retained four existing Heller 4-axis, twin-pallet, horizontal machining centres (HMCs) that were already on site. Within weeks, Autocraft was using them to produce cylinder heads and blocks both for its own engine assembly and for delivery to its customers’ production lines on a just-in-time basis. For Autocraft Co-owner Mike Hague-Morgan, it was a seminal moment.

He said: “We had always bought other makes of prismatic machining equipment. However, the typical six-day turnaround to source a new spindle from the suppliers meant that we had to carry £500,000 of extra stock of machined parts to ensure continuity of supply to our customers. It was not only costly but took up a lot of floor space.”
“Once we started using the Heller machines, we saw how quickly they responded to our requests for after-sales service, including the supply of replacement spindles within 24 to 48 hours. It gave us such a high level of confidence that we decided to take all the stock out and purchase additional Heller HMCs to produce more parts, increasing our profitability.”

Autocraft produces medium to low volume cylinder heads and blocks for a range of 3 to 6-cylinder inline and V6 to V12 engines for automotive and off-highway applications. The four Heller H2000 machining centres were soon joined by another three. Then two further orders, each for three more, were placed during the pandemic to bring the total to 13.

Mr Hague-Morgan added: “During an incredibly difficult trading period, we were still able to grow the business partly because of the service level provided by Heller, not just for the new HMCs we bought but also for the original turnkey package of machines we inherited.”

“In addition to rapid spindle replacement when needed, the supplier also provided installation support and sometimes engineering support as well, as we had staff on extended sick leave due to Covid.”

“Engineers from Heller came on site and seamlessly slotted in to support our team. That is not an average level of service, for which Heller has to be commended.”
“We deliver hundreds of engine blocks per week to major production lines and it costs millions of pounds if they stop, so continuity of supply of heads and blocks is critical. Having machines up and running within a day or two after a spindle failure is worth a huge amount to me.”

It is noteworthy that Heller’s compact, high torque spindles are produced in-house in a recently-opened, air-conditioned, automated facility at the company’s headquarters in Germany. They feature ease of servicing, integrated leakage checking to prevent damage, and programmable through-coolant up to 70 bar plus rapid run-up times for high productivity.

Although the H2000s in Wellingborough were designed by the parent company, they were manufactured at the group’s UK factory in Redditch. Contributing further to maximising output are fast rapid traverse, integral hydraulics for automatically clamping the engine components and air detect for checking that the component is seated correctly. A probe in the tool magazine for identifying broken cutters shaves off further time by removing that function from the cutting cycles. All these features are standard with Heller, whereas many other machine manufacturers class them as extras, increasing both cost and delivery lead-time.

With more than 400 staff and over £60 million turnover, Autocraft provides an array of engineering services to global automotive OEMs and their supply chains. It helps customers outsource non-core operations, such as offering a fully outsourced internal combustion engine (ICE) solution for manufacturers wanting to move away from in-house engine production, freeing up factory space and personnel to concentrate on electric vehicles (EV).

With environmental issues becoming increasingly important, the engine remanufacturing service is becoming ever more popular and the manufacturer also helps its customers to transition from ICE to EV technology. In addition to engine and component production, Autocraft is a technology leader in the repair, remanufacture and niche volume assembly of EV battery packs and electric drive units.

Who are Autocraft?

Autocraft Solutions Group is well known and respected as Europe’s largest independent engine remanufacturer and assembler, supplying over 20,000 IC engines per year to prestige OEMs such as Jaguar Land Rover, Ford, Volvo, PSA, Aston Martin, JCB and many more.

The global environmental shift from Internal Combustion Engines (ICE) to Electric Vehicles (EV) has led to Autocraft becoming a technology leader in EV battery remanufacturing solutions. Autocraft’s new REVIVE™ WORKSHOP EV Battery Service Centre in Grantham, Lincolnshire repairs and remanufactures up to 2,000 battery packs a year for several OE manufacturers. Autocraft also installs and staffs REVIVE™ WORKSHOP Centres at its customers’ facilities, for permanent on-site EV battery triage, diagnostics, repair and remanufacture. It is now introducing REVIVE™ MOBILE Repair Centres in transportable off-grid containers to bring the expertise to the customer, meaning packs can be tested, repaired and remanufactured on-site, saving time and shipping costs. Modules and cells are tested and graded, with those not meeting the high automotive State-of-Heath requirements re-used in 2nd life applications and only sent to its recycling partners if no longer usable. New for 2023, Autocraft’s REVIVE™ TRIAGE Mobile facilities are on-the-road vans with triage equipment and on-board diagnostics for non-invasive testing and repair of packs. It can make safe damaged ‘red’ packs for safer and cheaper transport to a REVIVE™ centre for repair.

Autocraft remanufactures Electric Drive Units and EV power electronics to provide a service product at a fraction of the monetary and environmental cost of fitting a new unit.

Prima Powers generations of automotive innovation

At the height of the summer heatwave, MTD magazine travelled to Prima Power in Turin where the technology was hotter than the weather! The Italian beacon of innovation is home to the HQTC (Headquarters and Technology Centre) and it is here that we witnessed demonstrations of the latest technology and learnt more about the company’s rich history – something that has set the standard in the automotive industry for generations.

As the laser and sheet metal business unit of the Prima Industrie Group which is listed on Milan’s Stock Exchange, Prima Power is a technology trailblazer. It is in an enviable position whereby companies within the Group are specialist manufacturers of mechatronic and optoelectronic systems, automation, software and more – creating complete autonomy over the development and manufacture of its technology. With a product range that encompasses 2D and 3D laser, punching and combined punch/laser and punch/shear machines, press brakes, panel benders, FMS and automation, and software, the company has eight manufacturing facilities spread across Italy, Finland, the USA, and China.

During our visit, we toured the HQTC – a facility that is home to the very latest technology the company has to offer. Not just a showroom, this innovation centre is also a test and demonstration facility where manufacturers from all sectors ‘prove-out’ and optimise their projects, finding the complete solution to their production issues. At the time of the trip, the HQTC presented a diverse range of technologies that included the Laser Next 2141 3D Fiber Laser, the Laser Genius+ 1530 2D Fiber Laser, the Print Sharp 150 powder bed fusion additive machine, the BCe Sharp Panel Bender, the eP-1030 Genius Press Brake and the jaw-dropping PSBB (Punch, Shear, Buffer, Bend). For engineers that cannot afford the time to make a trip to Turin, live video feeds of demonstrations and trials can be undertaken….although such an impressive facility is definitely worth the visit.

On approach to the Turin facility, the modern buildings with an architectural design akin to the style that is synonymous with high-end Italian fashion brands and sports cars meant we were in for a treat – and we weren’t disappointed. The reception displayed the Olympic torches from both the London 2012 and Rio 2016 – both produced on Prima machines and also an aerospace exhaust system, all demonstrating the bending, punching, cutting and forming potential of what we were about to see.

The Technology
With so much to see, it is impossible to discuss the HQTC and the machines within in the detail they deserve – but thankfully you can watch the MTD videos online. Starting with the eP-1030 Genius Press Brake, the 3m 105-tonne machine is the epitome of bringing technology and automation to what has long been a manual process. The O-frame machine with dual-servos provides an even distribution of bend force whilst the Genius element provides tool storage and automatic tool changeovers that make set-ups and changeovers an extremely fast and efficient step. The tool carousel stores 32m of tools, something that can be connected to two machines to reduce floor area, improve automation and create production autonomy. With worldwide skills shortages, power consumption and environmental considerations at the forefront of most business concerns – the eP-1030 ticks all the boxes with its low energy, low maintenance and simplified operation.

Alongside the eP-1030 was the BCe Sharp Panel Bender, a step further into the world of automation with the facility to manually or automatically load/unload sheets. With a control that allows parts to be processed individually, in batches or as kits, the sophistication of the Prima Power TULUS software suite makes programming, simulation, scheduling and storage a breeze for operators of the latest machine in the range.

With additive manufacturing technology increasingly penetrating the manufacturing sector, Prima Additive (the business unit of Prima Industrie Group dedicated to metal additive manufacturing solutions) has made its first 3D printing step with the Print Sharp 150 powder bed fusion (PBF) machine. The Print Sharp 150 utilises a single 300W laser with a layer thickness from 0.02 to 0.12mm that can reach a build volume of 150mm diameter and 160mm height – printing a diverse range of materials from stainless and nickel alloys to copper aluminium and more. With buzzwords like ‘circular economy’ being banded around the industry and more manufacturers conscious of reducing waste and looking at ways to repair failed components, Prima Power has also developed its 3D printing technology to go beyond PBF – offering Direct Energy Deposition (DED) technology.

The DED technology enables manufacturers to additively melt powder to areas of parts where it is needed. This can now be integrated into the company’s Laser Next (LN) Series of 3D Fiber Laser machines – opening a world of opportunity for manufacturers by retrofitting a DED head kit or even a laser welding head to existing fiber laser machines. To witness the potential of the Prima Power laser technology, we were given a demonstration of the Laser Next 2141 3D Fiber Laser. The largest model in the 3D Fiber Laser series, the LN 2141 offers 2.1G of acceleration and 4G on the C-axis. The speed and acceleration are possible due to a lightweight aluminium gantry and carbon fibre laser head that minimises the forces placed upon the structure whilst a synthetic granite base provides stability for a positional accuracy of 0.03mm. The lightweight design ensures the machine requires no floor foundation and the 2.1 by 4.1 by 1.02m work area can be configured into single or split cabins and tables, so one part can be unloaded whilst the machine is processing another part.

The LN 2141 on show demonstrated this concept with a split cabin. On one side was a fixture with the tailgate for a prestigious UK vehicle manufacturer being produced – and in the next cabin was a rotary table set-up. Commenting upon this, Prima Power UK General Manager, Mr Barry Rooney says: “Prima has been at the forefront of laser cutting since the 1970s when we developed the first 3D laser cutting system for the automotive industry. It all began when automotive companies moved to hot forming body panels to increase the strength and safety characteristics of vehicles. In the age of the modern vehicle and particularly EVs, this technology is more prominent than ever for another reason – light weighting.”

Cosworth brings OEM quality control to batch and prototype level production

‘Standing still is the fastest way of moving backwards in a rapidly changing world’, an oft-quoted phrase and an ethos that could well apply to world-renowned innovators Cosworth, whose latest facility upgrades keep them firmly on the front foot in the propulsion industry.

When Cosworth opened its state-of-the art Advanced Manufacturing Centre (AMC) back in 2015, the company attracted the interest of some of the world’s highest profile automotive brands. The focus on low-volume, high performance components gave Cosworth an advantage that it has continued to hold ever since, yet as high performance has become even greater in the intervening years, the company has had to invest to maintain its industry-leading position.

Recent upgrades to the AMC, an integral part of Cosworth’s Northampton campus, have allowed Cosworth to push for increased levels of quality and flexibility to meet exacting demands from itself and its growing roster of OEM customers.

Brands like Gordon Murray Automotive and Aston Martin have already benefitted from Cosworth’s pinpoint precision and performance, but with these latest upgrades, the company is ready to fulfil even more demand.

Housed inside the AMC are 11 Matsuura CNC automated machining centres with automatic pallet loading, and an Oerlikon-Metco SUMEBore plasma coating machine. Cosworth engineers have, however, put into practice what it preaches to its clients: constantly striving to make the best even better, especially where quality control is concerned.

Cosworth already has a high-quality production line with multiple measures in place, using precision equipment to track each part and prevent faults from being carried forward through the production process. The engineers have made changes in two key areas to meet their own exemplary standards.

Firstly, they looked into their cast component leak testing apparatus. Once a part has finished a machining operation, it is checked for leaks within its structure. Ensuring that there are no cracks between oil and water galleries, combustion chambers and cylinder bores is crucial to the reliable operation of high-performance engines.

“The outgoing system had two means of testing and no electronic data recording,” explains Process Engineering Manager, Martin Hall. “We had our hot water tank for two reasons: one, heat helps to expand the part, bringing it closer to its running condition, and two, you can detect bubbles coming out of it better. We would design bespoke sealing plates that cover all apertures of the part. It would then be pressurised with compressed air and placed in the water tank. The technician running the test would spend time looking for any tiny bubbles that may signify a small leak – or big bubbles if there’s a mass leak. Although it’s not the worst way to test a part, it’s not the best because there’s no measuring apparatus to determine its leak rate.”
In 2021, the Cosworth engineering team were briefed on a new project which would put the AMC to the ultimate performance test. It provided the ideal opportunity to begin development of new leak test equipment.

The new machinery, named the ‘Flexible Batch Production Pressure Tester’, incorporates a scanner to bring it up to the same level of data tracking as the rest of Cosworth’s manufacturing equipment.

Each part has a UID (Unique Identifier) marking on it; the scanner recognises this and records the results to a folder that it creates for every test on every part. Not only are the results saved to the UID on the network – with instant access to each component’s data sheets at any point in the production process – but it also prints out the results on a sticker which is affixed to the component’s route card. This ensure a two-step method of ensuring ‘no fault forward’ control within each of the pressure testing steps.

The leak testing function is comprised of a pressure tester that fills the components with compressed air. It then monitors how much air is leaking from the part, signified by a drop in pressure, and bespoke machined plugs that seal all orifices open to the air. Pressurised air can only escape if there is a crack or manufacturing defect. There is also a pass master and fail master to show that the machine is calibrated and working correctly. Daily tests ensure the results are accurate.

This scale of testing is usually reserved for production levels associated with large OEMs that can afford to make fully automated equipment, as they produce very high component quantities. Cosworth, however, has developed an innovative and cost-effective solution for its comparatively small-scale production runs, that can produce the same level of testing as fully automated equipment.

Moving onto the second newly developed piece of equipment: the DC (Direct Current) Tooling Flexible Cell. Within the manufacturing of engine blocks and cylinder heads – the primary function of the AMC – crankcases, blocks and heads need to be mated during certain machining processes, such as honing cylinder bores.

The modern architecture and design of the engine blocks means that they are produced in two halves which are then fastened together. It is critical that this is done with absolute precision and to the provided specification. Any deviation from the true tightening requirements would result in the two halves having incorrect tolerances; the efficiency, performance and, crucially, reliability of the engine would be severely compromised.

The latest design of what are effectively F1 engines that the brand produces for its customers, have tolerances and clearances on all oil pathways that are so critical that being microns out would spell disaster. Tightening of fasteners, when two components are being mated together for a machining operation, need to be completed with the utmost accuracy and perfectly repeated every time. This is the purpose of the DC Tooling Flexible Cell.

There are two pivotal tightening operations when it comes to engine components: torquing the fasteners to a predetermined figure, and then tightening to a specified rotation measured in degrees. All of this is done in a specific pattern. Traditionally this was carried out by a technician and a highly accurate torque wrench, but when it comes to engines as large as the V12s Cosworth is currently producing, the number of operations to successfully mate two parts becomes very high. One cylinder head alone can have a minimum of 26 bolts and that’s only on one side of the V.

What Cosworth wanted to achieve was to keep flexibility within its batch production area, yet retain quality control, performance, and repeatability.

Engineers designed a part delivery system made up of a turntable with two engine stands on it. One is staged where the tightening operations take place and the other one is where another engine is loaded ready for the tightening process. This enables two technicians to work together in the cell, one loading engines and the other performing the tightening operation. The net gain is a boost to the efficiency of the workstation.

The operation begins with the part being scanned into the system using the same UID system as the rest of the AMC. The system recognises the part, and the tightening programme is automatically selected to ensure the sequence is carried out correctly. The tool that tightens has encoders on it that position the device in the right location as the technician carries out the tightening sequence. The tool cannot then tighten the wrong bolt or nut out of sync. The machine records all the data to the UID and saves it to the network to complete the task. The technician can then move onto the next component and the process begins again with the scanning of the next UID.

Both of these upgrades to the AMC are a vital step in ensuring no-fault-forward production, repeatability and accuracy whilst maintaining the degree of flexibility Cosworth requires to meet its varying customer requirements. Any part Cosworth chooses can be taken through these two pieces of equipment, meaning that even within the prototyping phase of a programme, engines are receiving the same standard of quality as OE manufacturing, keeping Cosworth moving forward in a rapidly changing world – just as it always has.

Revving up for open season

This summer was the first post-pandemic opportunity we’ve had to get out, travel, spend time away from home and relax – and thankfully we’ve had some great weather to go with it. Although the inability to communicate with many business contacts as soon as the school gates close in July does pose the question as to why we don’t all ‘shut up shop’ for a month, like they do on the continent.

After a well-deserved break, we should all be back at work and excited about the autumn open house season that will be kicking off imminently. With the IMTS and AMB shows in Chicago and Stuttgart both taking place in September, the deluge of innovations in the pipeline should be enough to whet the appetite of every engineer. For those unable to get to the shows, open house events will provide a great opportunity to see the latest technology launched at the international exhibitions. This will start with Hexagon, the Carfulan Group, AXYZ, Bystronic, XYZ (Huddersfield) and ETG Ireland in September and the pace will certainly pick up as we head toward November.

At MTD magazine, our summer has been non-stop with visits to Prima Power in Turin, the Farnborough Air Show and countless subcontract machine shops that appear in this bumper issue. The Farnborough Airshow was opened by outgoing PM Boris Johnson, and throughout the week, 17 Ministers attended the Airshow alongside more than 30 MPs from across Government. Whilst some Westminster politicians are collecting their P45’s, the show proved positive for the industry with a strong backlog of aircraft and engine orders, billion-dollar global partnerships and contracts revealed by globally recognised leaders. Airbus and Boeing announced deals between them worth US$4.5bn to the UK with 277 confirmed Aircraft orders and a further 81 options.

In this issue, we also have an update on the UK automotive industry, which like aerospace is part of a global industry. The auto sector has been hit by chip shortages, the war in Ukraine, Chinese lockdowns, an industry re-structure with electrification, inflation, rising energy costs and much more – but the EV sector is showing promising signs with new players entering the market and 2022 sales to date being 6.5% up on 2021. We also have an update on the latest investment at Cosworth, which is enhancing the quality of their high-performance engines.

Volumes edge up in auto sector smashed by Covid and chip shortages

Automotive manufacturing in the UK is changing radically. Volumes are down for the fifth year straight but semiconductor shortages are easing and units in 2023 are expected to rise. Electric vehicles are rising fast, but supply chain blocks, high energy costs, business rates and skilled employee shortages all threaten the sector. Will Stirling reports.

At first glance, the UK car and vehicle industry looks much the same as it has for years. There are five global mainstream car makers in Britain, down from six: Jaguar Land Rover (JLR), MINI, Nissan, Toyota and Vauxhall. Honda’s final official day of car production was 30 July 2021. Engines are still manufactured by Ford in Dagenham, by Toyota in Deeside, by JLR in Wolverhampton and others – the UK has lost one engine manufacturer since 2019. Bus, van and truck domestic production all have largely the same footprint as 10 or more years ago.

What has changed is that volumes are down heavily and remain, for now, on a falling trend. There are some signs of recovery as key component shortages ease. Electric vehicle production is rising. There is more pressure on car companies than ever to change – to decarbonise but to manage intense change like inflation, component supply shortages and energy prices. Vans, or light commercial vehicles (LCVs), are the only segment to grow consistently in recent years. LCVs on the road has increased by 29%, to 4,604,861 units on the road in 2020, largely driven by growth in the construction industry, says the Society of Motor Manufacturers and Traders (SMMT). While as a trend commercial vehicle (CV) production is falling, the CV segment had its best six months in a decade, production growing over 64% in June.

It’s common knowledge that a big reason for low car production is semiconductor shortages. Semiconductor, or chip manufacture is confined to a few, very large specialist factories in Taiwan and one or two other places, and supply was hit hard by Covid. Other factors include the impact of the Ukraine war, lockdowns in China, structural changes in the sector, inflation, energy costs and the shortage of other critical parts. But this bottleneck shows signs of relief. June was the second consecutive month in which the UK car industry grew, up 5.6% with 72,946 car units built, and this was largely due to an easing in semiconductor supply.

Half-year health check: Despite this UK car production declined -19.2% in the first six months of the year, according to SMMT figures published in late July, with 95,792 fewer vehicles built compared with the same period in 2021. The group said from January to June 403,131 units were built, “representing the weakest first half since the pandemic-ravaged 2020 and worse than 2009 when the global financial crisis decimated demand.” The closure of Honda’s Swindon plant in 2021 will have had a big effect on total units, too. The output of hybrid, petrol and diesel cars declined, by -19.9%, -8.0% and -60.2% respectively in the first half of the year.

In May, monthly engine production increased 12.3%, the first growth since June 2021.

Jobs, suppliers and other metrics
A concerning figure is jobs. Employment in all areas of UK automotive fell to 781,800 in 2021, a loss of 41,200 jobs in two years. This spanned the Covid pandemic, but it is still a big fall – 5% of all jobs. Like the airline and other industries, after layoffs when production increases – as it is expected to, by 2023/24 to over one million vehicles per year – jobs will return but will the industry struggle to find skilled automotive fitters and engineers who have moved on? It’s a cyclical problem, which seems to be partly solved in Europe’s biggest automotive market, Germany, by Kurzarbeit, or short-time work insurance, that subsidises worker payments in a downturn. It’s a system that has never been adopted in the UK, where agency workers and rapid rehiring programmes seem to plug the gap.

The ‘real’ health of UK automotive can only be ascertained when the efficient supply of parts and the effects of the Ukraine crisis have both normalised. By then, as the 2030 deadline for ceasing the manufacture of non-hybrid/non-electric cars approaches, ICE vehicle production will likely fall again as car makers begin to mass produce electric models.

Electric vehicles
The production of battery electric vehicles (BEVs) has proven to be a bright spot for the sector, with 32,282 produced in the first half of 2022, a growth of 6.5% on 2021. This was boosted by a whopping 44.2% rise in June, making a record output of zero-emission vehicles for the month. This was in part due to £3.4bn of new investment (government and private sector) committed to the UK’s zero emissions in automotive in the year’s first six months.

It’s no surprise that electric, hybrid-electric and hydrogen-electric is the segment with the newest entrants. In recent years and months Arrival, Tevva, Switch Mobility, EV Technology Group, and Maeving for motorcycles have formed a growing list of new electric vehicle manufacturing companies. They join London Electric Vehicle, Wrightbus and other more established low or zero-emission manufacturers.

River Simple is a growing UK-based hydrogen fuel cell eco-car company, bucking the trend of electric powertrains and choosing a fuel cell platform. In June electric and hydrogen truck company, Tevva made history by launching the first hydrogen fuel cell-supported electric heavy goods vehicle to be manufactured, designed and mass-produced in the UK. The Tilbury-based company already had a full-battery electric HGV in production.

EV makers’ main challenge is to move from the proving stage to volume manufacture – the most difficult stage in any car company’s genesis. Electric-van and bus maker Arrival received EU certification and European Whole Vehicle Type Approval in June, an essential step for starting trials with customers in Europe. It is under some stakeholder pressure to produce its first production vehicles. Mainstream production was expected to first come out of its North Carolina, US facility and then its Bicester, UK site. It is expected to produce the first vans from Bicester, near Oxford in autumn 2022 and shareholders, suppliers and Arrival itself are eager to reach this milestone.

Create a competitive environment to build vehicles
Tough conditions including high inflation and sky-high energy costs are passed down to suppliers at all levels. Equipment and robotics suppliers talk of razor-sharp margins in automotive in 2022, making big projects hard to price and make money on. Analysis by SMMT in June showed that UK auto manufacturers face a £90 million increase in energy bills this year as costs surge 50% – a figure that may rise come the autumn. This sector already spends £50m more per year for energy than its EU counterparts, in Germany, France and Italy, with the UK having some of the highest electricity costs in Europe.

If policymakers are to limit the decline in car production and help accelerate the recovery, they must bring inflation under control, and provide carmakers with energy cost relief or subsidy, after the sector has endured what SMMT Chief Executive Mike Hawes says has been a ‘long Covid’. “From Covid impacts to component shortages, supply chain disruption to trade uncertainty, and regulatory change to rising inflation, the challenges facing this sector are immense,” he said. “Nevertheless, addressing the UK’s high energy costs is the industry’s number one ask.”

“Help with energy costs now will help keep us competitive and be a windfall for the sector, stimulating investment in innovation, R&D, and training – all reinvested in the UK economy. With the right backing, this sector can drive the transition to net zero, supporting jobs and growth across the UK and exports across the globe.”

And don’t ignore the vital future role of connected and autonomous vehicles (CAVs) to the UK economy. We can’t see driverless cars yet, or very few, but the CAV market is expected to be worth >£62bn by 2030 and provide +420,000 new jobs, let alone improvements in safety and accident prevention.

F-35 manufacturing operations reduce cost using automation

The Lockheed Martin F-35 Lightning II combat aircraft is a long-range supersonic fighter with stealth capability that enables it to evade detection and enter contested airspace. The F-35 also provides impressive connectivity, serving as a communications gateway to share its operational picture with allied ground, sea and air assets. On the ground, the same characteristics of speed, connectivity and technology are recognisable in the manufacturing operations of this fighter.

As the prime contractor for the F-35, Lockheed Martin works with a global supply chain of more than 1,900 companies based in the US and the 13 nations acquiring the aircraft. Lockheed builds the forward fuselage and wings in Fort Worth, Texas and the evolution of machining operations for the cockpit-area forward fuselage understructure demonstrates Lockheed Martin’s commitment to continuous improvement.

Almost five years after the first F-35s were produced in 2006, a multi-day Kaizen event examined the overall manufacturing process for improvement. Jeff Langevin, Manufacturing Technology Fabrication Lead, said the Kaizen sessions showed the transport and ergonomics of readying the fuselage for machining and drilling operations were not value-adding. “Moving aeroplane parts around a factory and transferring NC programs are interface tasks that don’t necessarily build aeroplanes, but they impact our ability to do so efficiently.” The original process used an overhead monorail system to pick up and move the fuselage and present it to different machine tools. Each move required a crane operator and personnel on the shop floor to rig the fuselage, rope off areas and shut down sites under the lifting path to assure shop floor safety. Transporting the fuselage section in and out of the machining locations required about ten moves between machines, including working above and below the fuselage, setting up step stools, ladders, scaffolds and platforms for technician access, as well as washing the fuselage clean of debris.

The team worked with factory automation systems provider Fastems to blend the machining and transfer operations into an integrated machine tool transfer line (MTTL), using flexible manufacturing system (FMS) technology. On the MTTL, a fuselage section is lifted into a Load, Unload, and Skin Installation (LUSI) station. The LUSI station, also built by Fastems, makes it possible for a single worker to raise, lower and spin the fuselage. Operators stay at floor level without climbing over or under the fuselage and can manipulate it to positions necessary to carry out operations. Before the Fastems line was installed, a move from the LUSI station to the wash station took hours and required multiple personnel. Now, the move takes two or three minutes and requires just one worker to push a button.

After this, an FMS stacker crane carries the section down the production line to a house-sized Parpas America Precision Milling Machine (PMM) that mills and drills the understructure of the fuselage to accept the F-35’s composite skin. Following that, the MTTL delivers the fuselage section to a Fastems-designed wash station where machining debris is washed off and dried. Then the transfer line takes the fuselage to a LUSI station where side skins are attached. Following this, the fuselage goes to a FIVES Group Auto-Drill that makes about 500 holes in each side of the structure and a tool preset booth monitors tool wear in real-time and dictates preemptive tool changes meant to avoid process interruptions. After that, the fuselage returns to the wash station and finally to a LUSI station to be prepared for the next step. Brian Sykes, F-35 Forward Fuselage Lead Specialist, said: “The forward fuselage team works hand in hand with the automation system to reduce time, increase accuracy and improve safety. We reduced hours per unit from 132 to 98 hours, which is a 34-hour or 26% saving. The number of monorail moves decreased from 18 to 2, and the system also improved ergonomics for mechanics’ manual drilling operations.”

The system was designed to be modular, with the understanding that it would be expanded as F-35 production increased. Phase 1, installed some 10 years ago, featured four LUSI stations, two PMMs, one wash station, one Auto-Drill, and a tool preset station. About six years later Lockheed added another Auto-Drill and a LUSI station. A third expansion added a third PMM. In the meantime, Fastems has continually developed its Manufacturing Management Software (MMS) that plans, runs, and monitors the production in the MTTL. Fastems worked with Lockheed’s technology group and workers on the line to assure that the integration is seamless and there is no downtime during system upgrades. Langevin said: “The MTTL shows our internal stakeholders and customers that we are committed to making the F-35 affordable. We want to add value to the program that goes beyond just machining faster. This means finding the areas of waste in between the machining processes and making things easier and safer for our workers. The Fastems system shows that there is a place for flexible automation in an aircraft assembly line.” There is now a 75% reduction in span time provided through the MTTL that enables Lockheed Martin to manufacture up to 20 Forward Fuselages a month.

Langevin continues: “The Lockheed/Fastems relationship truly does feel like a team. Sometimes we forget that we’re a supplier and a customer because we are working so closely together. We have a common goal to make things more efficient and that has helped us to take the transfer line to the next level and expand the system with minimal impact on our production.”

While in terms of hardware the MTTL has grown as far as possible, Lockheed and Fastems continue to work with the control software development and other ways to further understand how the system is operating and how efficiency can improve.

Lockheed has found opportunities to continue to work with Fastems in other areas of the manufacturing process. The aircraft plant is about to put into production a new Automated Structure Laser Cleaner (Auto SLC) system supplied by Fastems for the F-35 wing line. The system is based on a laser ablation scan head designed to automatically remove primers and other protective coatings from F-35 wing components. Auto SLC produces a pristine surface to which nutplates can be mechanically bonded without using rivets. The system eliminates manual sanding and solvent wiping that consumed significant time and yielded unbalanced results. Part of the companies’ ongoing relationship is a Fastems-proposed agreement in which it provided on-site support for the first several months of operation. “They are committed to giving Lockheed not just a piece of hardware but also something that’s going to help us take the next step,” Langevin said.

Aero industry ready for take-off

The 23rd of June was ‘International Women in Engineering Day’ and it was great to see social media light up with inspiring stories from female engineers that have such passion for the industry. According to Engineering UK, just 14.5% of UK engineers are women – a figure that has increased from 12% in 2018. In numerical terms, women employed in UK manufacturing had risen from 721,000 in 2016 to 906,000 by Q2 of 2020. To celebrate the achievements of the ladies in our industry, take a look at our special feature with Mandy Ridyard, Finance Director at Produmax. What an inspirational leader! Can we all be doing more to attract women into a fulfilling manufacturing career?
With the Farnborough Air Show from 18th to 22nd July, it’s also timely that we are publishing our aerospace industry report. The commercial sector is currently being dogged by potential summer strike action and staff shortages that meant airlines couldn’t fulfil their surge in bookings during the most recent school half term.
Beyond these short-term challenges, the future looks bright. 2021 was a year of recovery where Airbus and Boeing delivered 611 and 340 planes respectively, an increase from 566 and 157 in 2020. Currently, at around ‘rate 45’ Airbus is targeting a monthly production rate of 65 by next summer and 70 by Q1 2024, so things are on the up. Like commercial airlines, the manufacturing supply chain is facing difficulties. These currently range from equipment and material availability, skills shortages, inflation, energy costs and more. As always, for those bold enough to invest and face the ‘headwinds’ the rewards will soon follow. There are several ways to overcome the hurdles ahead, and in this issue, we address a few of these challenges. Will Stirling talks about ‘lean’ and ‘kaizen’ with GE Aviation and we have some fascinating insights into how automation can deliver a complete transformation for your business – our cover story on the F35 fighter is just one example in this issue.

Cyber-attacks are on the increase for many of the UK’s manufacturing firms

Three in five of the UK’s Manufacturing and Engineering firms (M&E) have suffered a cyber-attack (UK average: 45%), with ransomware attacks the most frequently experienced, followed by phishing emails and denial of service (DoS) data breaches. Of those firms who have suffered a cyber-attack, 68% have been the subject of increased incidents, and 50% have suffered a financial loss, according to independent research from Close Brothers Asset Finance.
The research also reveals that 65% (UK average: 52%) of M&E business owners have invested in staff training to help prevent cyber-attacks, and a further 60% have paid for additional cyber security in the past 12 months.
Has your firm suffered any of the following cyber-attacks:
l Yes, Ransomware attack 22% (UK: 17%)
l Yes, Denial of Service (DoS) Data breach 12% (UK: 9%)
l Yes, Phishing attack 12% (UK: 10%)
l Yes, Malware attack 6% (UK: 4%)
l Yes, a combination of these cyber-attacks 7% (UK: 5%)
l No 41% (UK: 55%)

Our view
“It is well documented that many businesses of all sizes have at some point suffered some form of cyber-attack, whether it’s a ransomware or phishing attack,” said Steve Gee, CEO of Close Brothers’ Industrial Equipment Division. “What our research shows is that company owners are not only more aware of the dangers posed by cyber-attacks but are taking action by investing in training or additional security, or a combination of the two.
“This clearly doesn’t come cheap but the potential losses, both financial and reputational can mean it is something all business owners will increasingly have to consider, if they haven’t already.”

Banks
Trust in banks’ IT systems is quite high at 76%, and there is still relatively high usage of local branches for services, with 62% (UK average: 66%) of Manufacturing and Engineering businesses still regularly visiting high street banks.
This figure would likely be higher were it not for continued closures – 54% of respondents have been impacted by branch closures, which is among the highest figures of the sectors polled.
When it comes to using cash, over two-thirds (68%) of Manufacturing and Engineering operations still use this form of payment:
l Yes, but only to take payments – 36%
l Yes, but only to make payments – 22%
l Yes, to both take payments and make payments – 10%
l No – 32%
www.closeasset.co.uk

Leading with lean at the genba at GE Aviation Wales

While commercial air travel faces delays this summer, the aerospace industry is preparing for a super growth cycle as demand for travel increases and underutilised aircraft need an overhaul. As part of the drive for continuous improvement across the business, GE Aviation Wales hosted its’ first Shingijutsu Kaizen Week to help prepare for the ramp-up. By Will Stirling

GE Aviation Wales (based at Nantgarw, South Wales) understands ‘lean’. Engineers and support staff here work on a huge series of aircraft engine maintenance, repair and overhaul (MRO) where they must skilfully combine a focus on safety and quality while driving to meet – and wherever they can exceed – customer expectations and requirements. As the world emerges from Covid-19, the output rate is increasing fast, as in-service aircraft are getting much busier.
From 6 – 10 June, as part of GE’s Kaizen Week, an annual week-long series of Kaizen events across all businesses, GE Aviation Wales hosted its first Shingijutsu Kaizen Week, a series of team-based projects to sharpen the skills and minds of its staff to find new improvements in work practices and learn from others. Most attendees were local to the Wales site, but about 20% came from GE Aviation’s sites globally, GE Healthcare, GE Renewables and the team included Larry Culp (Chairman & CEO, GE), a long-term lean devotee. The Wales team was also supported by Yukio Katahira, a Master Lean Sensei with over five decades of experience and knowledge. No pressure, then.
Lean business improvement principles, often known simply as ‘lean’, were originally derived from the Toyota Production System in the 1950s and 1960s. The system helps companies assess their processes systematically to increase product flow, reduce bottlenecks, eliminate waste and add value for the customer. Lean deploys the culture of ‘kaizen’, (‘kai’ meaning change and ‘zen’ meaning to make better) the Japanese word for continuous improvement, where a process that was improved yesterday can still yield more improvement today, and tomorrow. Lean gives GE Aviation, and all GE businesses, a methodology to break down, measure and improve; setting the new standard and then going again – continuously improving.

GE Aviation Wales is a global MRO facility that services the GE90 and GE90-115B, and the CFM56 (types -5 and -7) commercial aircraft engines. It occupies over 1.2 million square feet of workshop space and has two ultra-modern engine test facilities and a headcount of around 1,100 people. Larry Culp was a lean practitioner for more than a decade during his tenure at the US engineering group Danaher. GE practised lean already, but when Culp joined, he decided that lean will run the company – factories, offices, finance, and group companies. So, it was a coup for Wales to be selected to host its first Shingijutsu Kaizen Week, with Larry and several members of his staff in support.

Measure, improve, measure again
Existing work teams – across a wide range of MRO functions – were joined by participants from outside the Wales site, and building on their pre-work they got a ‘rocket start’ on Monday morning. Lean projects should be addictive to engineers who love solving problems: true Kaizen demands that you find a way to improve something, make the improvement, measure it – and then do it all again. The principle is that nothing is perfect, there is no ‘sixth sigma’ on the bell curve, and we can always reach a little higher to attain perfection. For some shop floors, you might wonder how a certain process can be better when it has been perfected over four or five decades of production. This is where the change in mindset comes in, and everyone has to lead with lean. With support from senior executive ‘fresh eyes’ (new to Wales, new to the aviation business) and the collective brain power of their team – with a healthy amount of sticky notes, pens and giant paper pads – Team Leaders worked to truly understand their value streams and mapped their processes.
And Katahira-san was on hand to challenge, prod, guide and push anything that looked like a soft target. By the end of Day 3, nearly all the teams had acquired the nickname ‘Stretch’, after having their targets stretched by the Sensei.
Safety comes first, centred on hazard removal and reduction. One team removed more than 10 safety hazards in the areas they worked on, and all teams reduced some hazards.

Some wins were quick and made a surprising difference. Unnecessary movement is a productivity-killer in factories and is difficult to control – people like to wander. “It was the case that after looking at our processes before Kaizen, we had – through no fault of their own, highly skilled and highly qualified aircraft engineers walking from point A to C via B to get a tool or part that was in the wrong place and what we needed to do was look at things in a new way,” says Managing Director, Nick Blakeney. “Simply by looking at it closely, understanding the movement flows our teams could identify this and remove hours of lost time.” Other improvements took longer and required deeper analysis. By the time results were shared on Thursday and Friday, the savings were profound.
For example, the Bulk and Detail Strip Teams (who are responsible for breaking down the entire engine into piece parts) took out more than 40% of the hours per engine while improving the safety rating of each area. The Dispatch team, who work closely with the maintenance teams to get parts that need repairs off-site into the shipping cycle, reduced their process time by 70% in the week and fundamentally changed the layout of their entire work area. The team responsible for Direct Issue Material eliminated 60% of the primary issue or barriers affecting standard work adherence in the Final Assembly team.
All the teams recorded demonstrable improvements over the week and, noticeably, often in high double digits. This proves that even a factory or business unit that believes it is operating efficiently when challenged, can find big improvements. Blogging on the event, VP of investor relations at GE, Steve Winoker, writes:
“I have been to several Kaizens, but this one was especially gratifying to see the changes that took place during the week. Changes that resulted in safer practices, higher first-time quality, faster turn-around time, and ultimately lower working capital and cost. And yes, I mean that took place in the period from the pre-work, through Monday, to proving out savings on Thursday and Friday.”
He added: “The dollars associated with these improvements will show up in lower costs, reduced lead time, faster turns, and more revenue and profit over time.”
But Nick, with the support from his senior leadership up to and including John Slattery (President & CEO, GE Aviation) is clear that the hard work starts now; it’s all about sustainment. Capturing a saving in time is great, but the real benefits come if you can sustain the action, make it a part of the employees’ culture and, literally, improve continuously.
“Our Kaizen Week was a huge milestone on our lean journey as a business. Learning lean, reading the books and doing the training all help, but nothing beats experiential learning. With the senior support we’ve had over the last month and the experiences our team have built up, everything feels turbo-charged now and we are heading into our 30, 60 and 90-day report-outs with confidence – but clearly, there is work to do. We know for our employees and for our customers around the world, that improvements over one week are not enough, we need to sustain, set the new standard and over time; go again,” says Nick Blakeney, Managing Director.
In sum, the Wales Shingijutsu Kaizen Week was a great success and has set the bar for GE’s manufacturing and maintenance sites that host the next one. Good luck in beating some of these numbers.

Produmax widens its net

Women are increasingly taking leading roles in precision engineering and high-value-added manufacturing companies. To celebrate this trend, MTD magazine is running a series to profile these game-changers and the firms they lead. The first is with Mandy Ridyard, Finance Director of Produmax. By John Yates.

When aerospace manufacturing boss Mandy Ridyard proposed seafood as her strategic response to the pandemic, her team of ‘engineering superheroes’ assembled on the shop floor could have been forgiven for thinking their charismatic leader had finally lost the plot.
“Covid was a disaster for aerospace. We had gone from projected growth of 20% to a halving of our turnover,” says Mandy, who knew she needed to pivot a business that almost overnight had become precariously dependent on the once-booming, but suddenly grounded, aviation sector.
“We went from a sales strategy based on creating capacity to meet the demands of ramped up aircraft production to one of creating sales to meet our under-utilised machining capacity. It was a complete 180 degree turn,” said Mandy, whose Bradford-based precision engineering firm Produmax, recently won MakeUK’s coveted national SME of the Year award.

The seafood strategy, she explains, was all about diversification and communication; the two ingredients needed to secure a prosperous future for the firm and its talented people. The new markets she identified were space, energy, additive, civil aerospace, other and defence – with ‘other’ as a catch-all for any drop-in-lap opportunities that didn’t take capacity from elsewhere. Hence the acronym – Sea Cod.
The image of a sea cod on the opening slide presenting the new strategy to her team was also a brilliant visual mnemonic and prompted smiles all round: not easy to do when facing such challenging headwinds. Instead of dependency on four major aerospace clients, the sea cod trawl has landed Produmax a haul that includes nuclear energy, satellite and space, fuel cells for hydrogen buses, aircraft electrification and automotive.
Mandy believes this diversification has enabled Produmax to resist drastic staff cuts, thus ensuring the firm’s mission to be ‘engineering superheroes’ is not jeopardised. By using the second furlough to allow staff to learn new skills in other roles she has improved the mental well-being of the team – many of whom had found the first furlough at home difficult – and made the business more agile to face future shocks.
Rather than retrench, Mandy is on-boarding and growing new talent to create a much more diverse and inclusive culture in the business: an ethos she and her husband, Jeremy, have embedded in the business since they took over the firm in 1997 following the retirement of the founder and a management buy-in/earn-out.

Back then, the business was focused chiefly on telecoms – which they both knew would soon migrate to low-cost factories in the Far East – and the workforce demographics reflected the UK average of 52 years old.
“We knew that was not sustainable so we diversified the business into aerospace and began to change the demographics of our people. Our latest recruits are 50/50 male and female and the average age has come down to under 35 years old,” said Mandy, who is a passionate advocate of diversity and apprenticeships and has the battle scars to prove it.
In the early years, when Produmax operated out of an old tannery building in Otley, it was almost as difficult to change the culture on the shop floor as it was to change the CNC machines. “Back then we had to lift the roof off the building to crane equipment in and out. We had world-class shop floor utilisation, but you needed to be a small size eight to squeeze between the machines. We also had girlie calendars and banter across the shop floor,” says Mandy who is no stranger to gender bias in the workplace herself.
“I remember my first meeting at a major packaging company, I was a graduate trainee and there were other graduates in the room but I was the only female and I was the one they asked to make the coffee,” says Mandy. When she came back with the tray of drinks she asked the manager whether he would like her to take notes too. “He got the message and never asked me again.”

Her approach to the girlie calendars was equally effective. Instead of ordering them to be taken down, she said they could stay, but she would be putting calendars of semi-naked firefighters next to them. The calendars disappeared and, as the workforce has become younger and more diverse, so too has the banter.
Changing the firm’s demographics requires a big commitment. It’s meant building close relationships first with further education colleges and, today, with local schools from secondary down to primary. From sending free bar ends to technical leads at local colleges, to using her growing cohort of skilled apprentices as ‘engineering superheroes’ taking the manufacturing message into schools, Mandy is changing the profile of CNC precision engineering in a region that boasts more manufacturing jobs than anywhere in the north.
“We don’t do that because we are nice people – which we are – but because it makes good business sense. If you increase your diversity, you have so many more people to choose from and better access to talent which is proven to increase your productivity – which is the number one priority for us and a priority for the West Yorkshire Combined Authority mayoralty,” says Mandy who is now very much engaged in helping policymakers across the region understand the vital role that advanced manufacturing has to play in ‘levelling up’ the North.
“You could say that Jeremy is the brains of the company and I am the mouthpiece,” says Mandy who is now Chair of the West Yorkshire Innovation network. When she asks people for an example of innovation the answer is invariably a product: the iPhone, the light bulb and the paper clip. “They never think of a process or service as being an innovation. Produmax is a very smart manufacturer, but we have never innovated a product, we make components and parts to the client’s design and to the quality they require. That makes us a service and that is where the innovation happens: making the processes on the shopfloor more productive.”
Alongside the Innovation Network, Mandy is also a leading light in Space Hub Yorkshire, where she has developed a ‘virtual space campus’ that connects 12 universities and 34 regional colleges across Yorkshire to ensure the region’s businesses understand how to get their fair share of funding and who to partner with across the region. One small step for Mandy; but potentially a giant leap for the region.

She attributes much of her ability to be the firm’s in-house marketeer to participating in Sharing in Growth, the Rolls Royce inspired management programme with the tag line: growing great businesses by developing great people. “It was only after this programme that I started to explore a more outward-facing role,” says Mandy whose initial reaction to Jeremy’s idea of engaging with the program was one of scepticism. Today she is an evangelical convert and the firm has twice won Sharing in Growth’s top awards.
“It made a huge difference. Neither of us – and our team – had had any recent management training. We were totally honest and open with them and absorbed everything like a sponge. We now have better acumen around the financials. Where we used to measure everything off the profit and loss, we now measure everything through a series of metrics that feed into this. It’s easy to think you are efficient when you’re growing, but this allowed us to see how much more we could do by being smarter.
“It also enabled us to become better at engaging and developing our people and in exposing the business to the wider world. But, really measuring engagement requires bravery because you don’t always get the feedback you want. There wasn’t really any bad stuff, but sometimes when you are trying your very best and that isn’t good enough the impact is a bit like your daughter saying she doesn’t like your cooking.” Devastating.
During the pandemic, these marketing and engagement skills have paid dividends. “We have marketed hard and worked massively on business development, collaborating on a new dedicated additive facility at Silverstone Park. We are now engineering more than ten new parts a month, which is hugely challenging. It’s a bit like being a start-up where everything you do is money hungry; the new work we are winning needs new tools, new materials, new programming and that doesn’t bring immediate profit. But we know we have a strong order book and the skills to fulfil it when the time comes to deliver.”
Over the last year, Produmax has taken on four new apprentices – “continuing with what we believe in, even though times are tough” – and broken the mould by promoting a 17-year-old female apprentice to the role of cell leader manufacturing the gearbox housing for the Boeing Dreamliner.
“The company has never had an apprentice in this role before, there has always been this time-served thing around engineering, but Jasmine is brilliant. She is also embarking on an engineering degree at the University of Nottingham University as part of the research-intensive Russell Group. This kind of appointment changes the dynamic of the business, it brings new thinking and new ideas that will enable Produmax – and precision engineers like us – to be more innovative and productive,” Mandy said. Now that is a catch worth landing.

MACH meeting yields immediate results

Approaching 20 years in business, Hi-Spec Precision Engineering Ltd has evolved from a small start-up business to an established subcontract manufacturer that has fully embraced the latest CNC and automation technology to drive growth. When the company was having issues with holding tolerance on a boring operation, the Market Overton company visited MACH 2022 to find a solution – it was found on the Horn stand.
Since its inception, Hi-Spec has made a natural progression through manual and CNC machining to 5-axis and high-end CAM, pallet loading and automated machining with capabilities including everything from conventional and CNC machining to grinding, lapping, honing, welding and fabrication, hydraulic pressure testing and assembly.
The workload at Hi-Spec encompasses everything from agriculture and aggregate, construction, motorsport, fluid power and electric guitars. The components at Hi-Spec include hydraulic valves and cylinders through to equipment for the quarry and aggregate industry, producing anything from prototypes and small batches up to production runs of 10,000+. The company is also renowned in the music industry, manufacturing custom precision-crafted electric guitars (www.graingerguitarparts.com).
On a recent project to machine 400 mild steel latch components, Hi-Spec was having an issue holding a 9µm tolerance on a 26mm diameter bore that needed to be machined through a 25mm thick plate. Producing the parts on its 10-pallet Kitamura Mycenter HX250iG horizontal machining centre with a BT30 spindle taper from Dugard, the company was struggling to retain repeatability.

Hi-Spec Precision Engineering Ltd Managing Director, Mr Darren Grainger says: “We were having issues keeping tolerance. We tried two different brands of precision boring heads with a variety of cutting speeds and feeds, but the tolerance would deviate over a batch of eight parts on each tombstone. With a precise and robust workholding configuration on the Kitamura machine that is known to be the epitome of precision, we knew that the cutting tools and the tool set-up was the issue.”
The holemaking process included drilling the mild steel plates to 18mm diameter and then milling the bore to 24.9mm and subsequently applying a high-end boring head to achieve a diameter of 26mm that is tied to a 9µm tolerance.

A visit to MACH 2022
“We decided to find a solution at MACH 2022. We looked around and we recognised that Horn is a leading brand when it comes to holemaking. We discussed the application with Horn’s Steven Kilpin and it was suggested that the URMA reaming system would be a viable solution. In less than a week, the tool with special tolerance inserts for the non-standard hole size was supplied – we were blown away!”
“Steve visited our facility and checked the installation and proved out the speeds, feeds and accuracy. The first thing that stood out for us was the speeds and feeds of these tools. We are running the new Horn URMA system at 2200rpm with a surface speed of 180m/min and a feed rate of 2200mm/min. At these speeds, it is less than two seconds to ream and retract from the hole. The previous systems we tried was taking 18 seconds to feed in and out of the bore, so the Horn system is making an incredible cycle time saving for us.”

The Horn reaming system manufactured in partnership with Urma AG, Switzerland is a modular system that caters for diameters from 7.6 to 200.6mm and it is particularly successful for applications in steel, cast iron, aluminium, titanium and inconel. Commenting upon the application, Horn said: “For this particular application with a 9µm tolerance through bore, we opted for the uncoated cermet grade. One slight issue was the BT30 spindle, as we don’t have a standard adjustable chuck for this. This provided an opportunity to test the relatively new compensation sleeve that allows us to adjust the insert holder runout using four peripheral screws similar to a 4-jaw chuck, to within the recommended 5µm tolerance band. Usually, we would use a run-out adjustable chuck on smaller sizes or integrated adjustable shanks on larger sizes.”
“Another problem we encountered was the lack of through spindle coolant. We would usually insist on high pressure through spindle coolant for this application as our insert holders have coolant holes directed at the cutting edges. However, as the through bore was relatively shallow, flood coolant was the only available option and it seems to be coping well. We were confident that the 9µm tolerance wouldn’t be an issue, as we have previously held tighter limits than this with other customers,” said the Horn engineer.
Providing his take on the situation, Darren continues: “It is always great to have the speed, but if the tool doesn’t last or hold tolerance, it becomes less impressive. So, we needed time to see how the new Horn URMA system was going to perform on a production run. The results have been amazing. Almost a month after installing the system and we have machined over 200 parts – and each one has been checked on our CMM. Undergoing this stringent quality assurance process, we have found that this reamer is still holding size and it fluctuates by no more than 4µm within our 9µm tolerance band. This impressive result is giving us complete process stability and confidence that we can machine these parts at speed whilst demonstrating unwavering precision and repeatability to meet the demands of the customer.”

Equally important to a manufacturer like Hi-Spec is the surface finish that can be achieved, alluding to this, Darren adds: “Despite running at high speeds, the surface finish is still below 0.8µm and the cutting head looks like it’s barely been used. We are always pushing the boundaries of what we can achieve, but this tool has blown us away with its performance, precision and repeatability and exceptional tool life. We really can’t thank Steve from Horn and Roman at URMA enough for sorting out this problematic project for us.”
Concluding on the new tooling installation, Darren says: “We are hoping that this batch of 400 will be the first of many and the job turns into an ongoing project. If this becomes the case, the cycle time savings will be significant as will the tool life savings. Most importantly, the Horn system is giving us confidence that our parts are going to conform to the very tight tolerances on this job whilst delivering a very good surface finish.”

Mastering the holemaking process

ISCAR’s invention of the MULTI-MASTER tool line had a considerable impact on the world of cutting tools at the turn of the last century. The three-pronged principle of the MULTI-MASTER family was based on the face contact between a carbide head and tool, centering the head by use of a short taper to secure the head in the tool body by use of a threaded connection. It was the last of these three elements that benchmarked the connection of carbide heads in assembled tools.
The successful design of the thread, made of hard but brittle carbide, enabled fast and simple head replacements and created the easy-to-use tool that features ISCAR’s no setup time phenomenon. The threaded connection quickly found its way into various tool assembly systems with exchangeable carbide heads. This is now an industry standard.
At first, the MULTI-MASTER line was intended specifically for milling in the mould and die industry. Soon after, the automotive, aerospace and general machinery industries adopted ISCAR’s MULTI-MASTER in their production processes. Milling remains the focus of the MULTI-MASTER line, which now lends itself to drilling applications as well. The MULTI-MASTER line has greatly expanded over the years, and now covers a broad range of applications that include drilling, countersinking and chamfering hole edges. When looking back over more than two decades, it is apparent that the MULTI-MASTER line found its way into the holemaking sector of applications by providing highly effective solutions.

There are two types of heads which create the cutting section of the MULTI-MASTER tool. The first type is similar in its shape to a multi-flute solid carbide tool but differs in the overall and cutting-edge lengths. Increasing the number of flutes on the cutting head makes cutting more stable and productive. The heads of the first type are produced from stepped cylindrical blanks by use of a grinding operation. The heads of the second type are shaped beforehand by pressing and sintering with a minimal oversize. Additional grinding defines the final shape of the MULTI-MASTER head and its accuracy. The heads of this type have only two flutes characterised by high strength. This facilitates increased feed per tooth in comparison with the heads of the first type. Pressing technology enables the production of diverse complicated MULTI-MASTER geometric shapes.
The head is mounted on a holder that may be an integral body (shank) or an assembly comprised of a shank, extension and reducer. The holder is a rotating solid tool with cylindrical and conical sections without flutes that allow the evacuation of chips. MULTI-MASTER drilling heads are suitable for relatively shallow holes. This may pose a limit in holemaking applications, yet for short-hole drilling when the shape of a part or a work-holding fixture requires a high tool overhang, a MULTI-MASTER long-reach tool is more rigid compared to a typical drill with flutes.
The MM HCD two-flute heads stand tall above other MULTI-MASTER hole-making products. These extremely versatile heads are made with various point angles – 60, 80, 90, 100 and 120 degrees which ensures a wide range of applications such as centre drilling, spot drilling, hole chamfering and countersinking. They enable conical holes for countersunk screws, bolts, and rivets according to ISO/DIN/ANSI standards in solid material. If the workpiece is pre-drilled, countersinking efficiency can be improved by using multi-flute MM EDF heads that increase productivity in chamfering operations. When chamfering or deburring the back side of a hole, the MULTI-MASTER double-sided chamfering heads are the solution.

Centre drilling is one of the most common holemaking operations. High speed steel double-sided centre drills have been the common tools used for decades to achieve a low-cost solution. ISCAR’s new MULTI-MASTER centre drilling heads have won undeniable popularity by providing increased tool life and productivity, even under strenuous cutting conditions.
NC spot drills are also commonly used tools. Characterised by their small cutting depth, these tools are primarily used on CNC machines for creating pre-holes that allow precise drilling without the use of guide bushings. For machining shallow holes, the MULTI-MASTER line has great advantages with NC spot drilling heads. A thin web at the head point prevents ‘drill walking’ or deviation during the machining operations. In addition, as a result of the 90-degree point angle, the heads can be applied to hole chamfering.
Flat bottom holes are commonly created in many applications. Such holes are needed for seats of springs, sockets of screw heads or the ports of washers. The simple way to produce these holes is by drilling with flat bottom drills. If the drilling depth does not exceed 1.2XD, the MULTI-MASTER provides two-flute heads. The heads are suitable for drilling holes on slanted surfaces, featuring versatile cutting geometry, which allows the machining of most engineering materials.
Over recent decades, MULTI-MASTER has quickly expanded its field of use and established itself as an effective tool for holemaking as well. ISCAR’s engineering design concept which features over 40,000 tool options has anchored itself to become much more than a milling line. It now features many more options for drilling with ISCAR’s ‘No Setup time’ phenomenon to assure fast indexing and minimum machine downtime.

Quickgrind takes-off with new barrel tools

W

ithin the aerospace sector OEMs and subcontractors alike machine a wide range of materials, some difficult, some relatively easy. Here at Quickgrind, we have developed many ranges of solid carbide cutting tools that have proven very successful whether endmills, high feed, special tools or barrel-type tools.

Let’s take a look at three examples – the Caiman, the Mirage and the Eliminator. The Quickgrind Caiman is a high-performance range of end mills for machining 6000/7000 aluminium and it is available with various corner edge preparations such as chamfer, radius or square end in diameters from 3 to 25mm with 3 or 5 flutes. When looking at improving productivity with trochoidal milling, we also offer all of these tools with chip breakers. This enables our tools to achieve full flute engagement with the benefit of producing small swarf chips that are easy to handle and do not disrupt the machining process. The tool dimensions are offered in stub, standard and long overall lengths with a vast variety of flute lengths to suit your applications.

The Mirage is a favourite when machining heat-resistant materials such as stainless steel, titanium and inconel. Available in 4, 5, 7 or 9 flutes with chip breakers if required and in virtually any combination of overall length and flute plus radii you can think of! When the application requires that bit extra, we now have our Mirage Super which is capable of achieving excellent performance especially in roughing operations. With diameters from 3mm to 25mm, we can support your requirements at every step. 

‘Eliminator’ was chosen as the name for our barrel tool range because this is what it does, it eliminates your frustration with long finishing cycle times. Available in conical, tangential, lens and Type F forms, we have also recently introduced our new concave form. These tools are transforming finishing strategies in a variety of components from blisks and impellers (multiple or single-bladed) to aluminium aircraft structures with deep pockets and side walls. Replacing the need for time-consuming scanning with ballnose endmills, our tools are available in bespoke tailor-made forms with deliveries of 2-3 working weeks for the standard series. With these groundbreaking tools, full application support is available – all the way from tool design to prove out and application.

The new concave barrel tool is an exciting new addition to our range and it is designed with a concave flute as opposed to a convex flute. This exclusive new design from Quickgrind has been developed by our R&D engineers over the past 18 months. It has proven to be an excellent tool for components with convex surfaces such as femoral knee joints for example. We are currently running trials on some aerospace and motorsport parts and the early results are very positive.

A greener future for aerospace

As one of the largest contributors to global CO₂ emissions, there’s an urgent pressure on the aerospace industry to provide greener aircraft that are lighter and can travel for longer distances. However, achieving this requires working with tough-to-machine aluminium and heat-resistant superalloys (HRSAs). Here, Sébastien Jaeger, Industry Solution Manager – Aerospace for Sandvik Coromant, explains how aerospace OEMs can adopt advanced tooling solutions to sustainably machine these tough components.

According to the World Economic Forum (WEF), ‘Achieving net-zero CO₂ emissions by 2050 will not only help create an environmentally sustainable future but also ensure a financially resilient and competitive aviation industry as a whole.’ While e-mobility has become increasingly established in the automotive sector (August 2021 saw electric vehicle sales overtake sales of diesel in the UK) these developments will take longer to materialise in aerospace. 

Generally, electrified aircraft are not expected to reach widespread use until 2035. Lonely Planet reports that, although easyJet hopes to run electric planes on routes under 311 miles (500km) by 2030 and Norway aims to make all short-haul flights electric by 2040 — ‘we won’t be flying long-haul on rechargeable jumbos any time soon: batteries are simply too heavy.’ So, while batteries do need to become lighter to be plausible, there is also a growing onus on OEMs to manufacture lighter components to counterbalance the problem. We can be sure that aluminium — specifically, new types of aluminium with greater strength, fatigue resistance and other attributes will be used to make these systems lighter.

We’re also seeing increasing use of new HRSAs. HRSAs are already used in aircraft parts that face extreme performance demands because they retain their hardness when facing intense heat. The material properties will prove essential, as one approach to more sustainable air travel will be to burn the engines harder and hotter.

Components must also be produced to tighter tolerances and more varied designs. As with e-vehicles, tomorrow’s electrified aircraft designs, including the airframes and the engines — will vary more from manufacturer to manufacturer than existing internal combustion engine craft. For the airframe, some OEMs are exploring the delta shape, blended wing body and strut-braced wing concepts. Other OEMs are sticking to traditional ‘big tube’, wings and an engine type design. 

There will also be different forms of engine architecture like electrified, battery-driven or electromagnetic or hybrid engines where current engines are assisted by electric power motors. OEMs will be required to produce an increasing variety of components to tight tolerances while also finding new ways to reduce noise, weight and emissions — all factors that influence how electric systems perform. But aluminium and HRSA components are difficult to machine, so achieving this sustainably and cost-effectively will be a challenge.

Rapid progress 

One path to producing lighter and more fuel-efficient aircraft is through additive manufacturing (AM) techniques. AM allows the development of very complex-shaped customised parts and functional products to tight tolerances, so difficult-to-machine parts like lattices can be machined more easily. According to findings by software company Dassault Systemes, ‘in the aerospace sector, weight reduction from AM processes can result in energy savings of up to 25%,’ while ‘each kilogram of weight loss on a flight can save up to US$3,000 in fuel annually.’

But is AM manufacturing itself sustainable? A study, co-authored by the Department of Manufacturing Engineering at Romania’s Technical University of Cluj-Napoca, describes AM as ‘a great alternative to Traditional Manufacturing (TM) methods like injection moulding, die-casting or machining.’ It continues: ‘AM has the potential to lower costs and to be more energy-efficient than conventional processes.’ 

We’ve looked at how aerospace OEMs can adopt new methods to produce more complex components. But what about having the right tools for the job — particularly when machining tough aluminium and HRSAs?

These materials necessitate the use of tools with higher wear resistance and longer tool life. That’s why Sandvik Coromant developed the S205 grade for steel inserts used in turning. The S205’s metallurgy includes an Inveio® layer of tightly packed, uni-directional crystals. This creates a strong protective barrier around the insert to strengthen the tool and enhance its mechanical properties. The insert has already proven useful in manufacturing a range of aircraft components including engine turbine discs, rings and shafts. Sandvik Coromant’s customers have already reported 30 to 50% higher cutting speeds with S205 when compared with competing HRSA turning grades.

Holistic approach 

We have considered manufacturing processes and tools, but how can we best combine the two? After all, time can be wasted in putting together a fully-integrated solution. Especially, if the systems aren’t designed to play well together. To this end, Sandvik Coromant is supporting its aerospace customers with ‘a components solution’. The solution has several stages including looking at the machine requirements and time studies to examine the cost-per-component. Also, analysing production methods at the run-off, relating both to Methods-Time Measurement (MTM) and end-user processes. The component solution also includes CAM programming and project management of local or cross-border projects.

For one Sandvik Coromant customer that was experiencing chip breaking problems in its production, the components solution allowed us to spot the cause and devise a solution. For the customer, Sandvik Coromant’s specialists developed a new strategy with dynamic drive curves that allowed us to control the chip breaking in every moment. We called this new approach ‘scoop turning’ and we now have a patent over it. With scoop turning, the customer achieved an 80% cycle time reduction with great chip control and it doubled the tool life.

What’s more, the customer was able to reduce its use of four machines down to one, reducing the need for multi-tasking, with more secure machining processes and green light production. Reduced machine usage and the ability to complete production runs with fewer tool changeovers were possible with tougher machining grades like S205 which will be key to more sustainable aircraft production.

The software will also play a vital role, such as the CoroPlus® Tool Guide that is part of the Sandvik Coromant’s digital portfolio. Customers can make crucial decisions on the choice of tool and cutting parameters before they have even commenced production.

Close the loop

Aside from new approaches to tools and manufacturing, aerospace OEMs can also turn to their manufacturing processes. According to a report by the Air Transport Action Group (ATAG), Kaiser, the company that supplies aluminium to Boeing, now employs a closed-loop recycling system — one of the largest programs of its kind in the industry. Kaiser estimates that around 10m kg of offcut and scrap metal will be reused by the industry, each year, through the scheme. At Sandvik Coromant, we’ve initiated our circular system for recycling carbide tools where we ‘buy back’ customers’ worn-out carbide tools and re-use them to make brand new ones. As a result, most of the raw materials used in Sandvik Coromant’s cemented carbides tools now come from scrap. We practice sustainable business in an environment of limited resources and minimise excessive waste. By doing this, we’ve found making tools from recycled material requires 70% less energy, while 40% less carbon dioxide is emitted.

There is mounting pressure on the aerospace industry to manufacture greener aircraft that are lighter and travel for longer distances. However, with the right processes and tools in place — not to mention a more holistic approach to manufacturing, aerospace OEMs can do their bit to help establish a greener future for aerospace.

Hollingworth expands with input from Ceratizit

Starting Hollingworth Design in 2005, Paul Hollingworth was working from home offering his extensive engineering design knowledge on a consultancy basis – something that has now evolved into a multi-million pound business. The company still offers design consultancy as well as developing its range of industrial compressed gas and vacuum systems and expanding into subcontract machining.

Paul built up from design work to the machining of prototype parts, initially with two small machines housed in his shed. As demand grew, the need for a more formal set-up became too much to ignore, so a move to a 4000ft2 facility in Denton with the arrival of a turning and machining centre from XYZ Machine Tools were the next steps.
“We looked at the numbers and the reluctance of other subcontractors to take on our work, having machining in-house was the logical conclusion,” says Paul Hollingworth, Director, Hollingworth Design. Seeing further growth opportunities by having this machining capacity, it wasn’t long before further investment was made and the move to subcontract machining services blossomed and drove a move to its present location, a 12,000ft2 facility in Stockport.

Now, the company has two Index bar-fed mill/turn centres, a G200-2 and a C100 machine. The machines have provided powerful B-axis capability and simultaneous cutting with up to four tools. “Any job that can be machined from bar is classed as a turning job, and goes on these machines, even if there is no actual turning involved,” says Paul Hollingworth. Applying this philosophy, allows cycle times to be drastically reduced, with help from Ceratizit UK & Ireland.
One component destined for use on superyachts, benefitted from Ceratizit’s input. Initially, a four-flute 6mm diameter milling cutter was being used on the 303 stainless steel components. With a recommendation from Ceratizit Technical Sales Engineer Matt Darbyshire, this was changed to a five flute Silverline solid carbide high-performance cutter from Ceratizit’s standard range. Running this cutter at 6250rpm and 0.1mm/rev feed rate with a 1.5mm step down every revolution, this cutter completed the entire batch of 4000 components without being changed.
“The performance of this cutter simply blew me away, we achieved a ycle time of 3.5 minutes per component, running the machine 24/7 and meeting all of our customer’s expectations.” This is a typical example of the approach that Hollingworth Design takes. It looks at every aspect of the job and engineers a process to make things better. To maximise the benefit for customers, Hollingworth Design looks at batch quantities from 500 upwards, recently completing a single order for 72,000 components. Machining these volumes demands support from Ceratizit in the form of regular visits from Matt along with daily management of tooling through the use of a Ceratizit TOM 840 tool vending system.

“Our turnover has grown dramatically in recent years with subcontract machining accounting for around £150,000 per month from our overall monthly turnover of £600,000 per month,” says Paul Hollingworth.
“Managing the tooling requirement for this level of work needed to be streamlined and where possible we had to eliminate the last-minute verbal orders for tooling to comply with our ERP system and maintain 24-hour operation.” Having the TOM 840 in place provides much greater flexibility for Hollingworth Design by having tooling available when needed, stock automatically re-ordered and restocked, without any requirement for in-house management time or added costs, with the tooling only invoiced when it is used.
The Ceratizit TOM 840 unit is also supplied and installed free of charge to any customer meeting the minimum monthly spend of £3000. Hollingworth Design also takes advantage of the Ceratizit re-grind service, which provides a quick turnaround for all of its solid high-speed steel and carbide cutters, returning them to ‘as new’ performance.

Speeding up deliveries with XYZ

Seal Team Systems creates bespoke leak repair systems for food manufacturers, energy generators, water suppliers and hospitals, providing on-site leak sealing technology to minimise any disruption or downtime. This can be expensive or life-threatening.
The leaks can be anything from 150psi steam in industrial/hospital scenarios, to super-heated steam at over 1000psi (70Bar) at temperatures up to 700°C. Time is critical in manufacturing a range of components that can create an effective leak repair that can be made permanent at the next scheduled maintenance shutdown.
With every leak posing different problems, the parts manufactured by Seal Team Systems are bespoke. The process starts with a customer site visit by a trained technician who reviews the problem, takes detailed measurements and as soon as he returns to the factory, manufacturing starts. All this can take 2-3 days, a situation compounded by a reliance on manual machining, a time loss that is unacceptable to many customers, with one quoting a £3m cost for a 3-day shutdown.

To address this, Seal Team Systems has invested in an XYZ RMX 5000 bed mill fitted with the latest ProtoTRAK control system. “We recognised a need to automate the process as much as possible, especially as finding skilled people was becoming harder,” says Andy Mills, Director Seal Team Systems. “With the XYZ RMX 5000, the technician can now simply text all the details to us and we can start machining straightaway, turning what was a 2-3 day process into a next day service.”
The XYZ RMX 5000 is the largest machine in the ProtoTRAK bed mill range and is equipped with a 7.5hp programmable and variable speed spindle, with 3-axis CNC provided by the touchscreen ProtoTRAK control. With a table measuring 1930 by 356mm and axis travels of 1524 by 596 by 584mm, it is large enough to handle most jobs. A key feature for Seal Team Systems is the TRAKing facility built into the control. This allows operators to use the handwheels to move through the CNC program, at a speed they are comfortable with, even allowing the program to be reversed if required.
“The move to the RMX 5000 with the ProtoTRAK control was a logical step up from manual machining, the training was straightforward, and we were operating it very soon after installation,” says Ken Black, Director, Seal Team Systems. “The time savings are significant, and typically amount to a 66% reduction in lead times. Being new to CNC, we were also impressed with the support given by XYZ. Before ordering, we had demonstrations where we brought our own materials. XYZ also modified the showroom machine to provide air cooling to the cutter, rather than coolant, which was our preference.”

The arrival of the XYZ RMX 5000 also brought other changes to Seal Team Systems with an investment in Autodesk’s Fusion 360 CAD/CAM software. “With the RMX 5000, we can machine parts we couldn’t attempt before on our manual machines, such as out of round/oval parts such as valve bonnets. This has opened up new possibilities for us and the software allows us to be more creative and make use of FEA, meaning we can give added reassurance to customers and avoid over-engineering parts as we have had to do previously,” says Ken Black.
Business for Seal Team Systems was good before the arrival of the XYZ RMX 5000, but since its arrival, they have seen an increase in turnover and the result is the need for additional people to handle extra work being generated.

One-hit production reduces lead-times

T&R Precision Engineering recently started manufacturing parts from inconel 625 castings for the hot air side of the GE-Safran LEAP-1A turbofan that powers the Airbus A320neo family of single-aisle jets. The problem was that the work involved a labour-intensive sequence of three or four operations on separate machines. Not only was there a significant risk of introducing human error, but it also necessitated the production of a batch of eight components to start each day. Each batch would take one week to complete for the Foulridge, East Lancashire company.
A more efficient process route for the drilling, milling, chamfering and turning operations was sought by the aerospace components supplier. The ideal solution identified by Engineering Manager Graham Gilbert involved the purchase of an Okuma MU5000V 5-axis VMC from NCMT served by a 6-axis industrial robot.
Managing Director Tim Maddison commented: “The improvement in production performance has been enormous across the four different LEAP-1A castings. All parts are now produced in one hit in a one-hour cycle, which means that eight components are now ready the same day rather than after a week. The substantial saving in lead-time is accompanied by vastly less workpiece handling and work in progress on the shop floor, while at the same time, fewer free-issue inconel castings need to be supplied by our US customer at any given time, saving them money as well.”
A further benefit is a 50% reduction in total processing time compared with when the parts were produced in three or four separate operations. An additional saving that Mr Maddison describes as ‘massive’ comes from inspecting every completed part in the VMC in a 10-minute routine at the end of the cutting cycle. So instead of 100% inspection on a CMM, only one part per day now needs to be checked off-line.
The production cell was installed in November 2019, shortly before the start of the pandemic. The aircraft build rate promptly collapsed from 63 per month to zero, but Mr Maddison advised that by the start of 2022 it had recovered to 50 per month, will return to pre-Covid levels by the end of the year and is predicted to rise by a further 20% through 2023.

The contract machinist could not have coped with these increased volumes without investment in the Okuma but is now in a position to take full advantage. The layout of the equipment is such that, there is space for a second Okuma MU5000V to be installed adjacent to the first and to be served with pallets of pre-fixtured components from the same Cellro robotic store.
Several notable technical advances have been incorporated into the latest production cell. One is the provision of Okuma’s turn-cut software in the proprietary OSP machine control that allows, without the need for special fixturing, turned features to be produced that are not on the centreline of a component. Three of the castings require this technology to be used.
Features are machined by rotating a turning tool in the VMC spindle, circular interpolating the X and Y axes at the same rotational speed and feeding the spindle forward in Z. Had interpolation turning not been available, it would not be possible to produce all the parts in one hit. There is no production efficiency penalty through the use of relatively slow turn-cutting, as it is not feasible to turn inconel at high speed due to the material becoming difficult to machine when hot.
To compensate for there being a lot of variability in the shape of the castings, another process improvement is the use of a combination of Renishaw’s Inspection Plus and Productivity Plus probing software packages running in the control coupled with spindle probing of the workpiece. The various elements of a casting can be measured and manipulated by the measurement cycles so that the workpiece can be placed in a position where it can be machined successfully; and if it cannot, the part will be rejected.

Another feature of Okuma machines that T&R Precision appreciates is the Thermo-Friendly Concept design, involving both the machine structure and the spindle. It allows the aero-engine parts to be machined to within ± 25 microns, despite a significant variation of temperature on the shop floor in Foulridge.
Space for 30 machine pallets in the Cellro store allows up to 30 hours of production without operator attendance, so there is no need for a manned night shift and full advantage can be taken of lights-out operation at the weekend. With an OEE (overall equipment effectiveness) over 80%, it adds up to a highly productive facility in its present form, while the flexibility to add a second VMC has the potential to double output and extend unattended running further.

Taking the right turn

As a manufacturer and stockholder of high-integrity bolting, Beck Prosper Ltd has recently invested in a large Leadwell LTC-35CL turning centre from Whitehouse Machine Tools. The new acquisition will enable the Kingswinford manufacturer to increase the capacity, and productivity and also enhance the quality levels of components the business manufactures.
Robbie Beaman from Beck Prosper says: “The part on the machine at the moment is a long fastener, and on the lathes that we already have, they do not have the length capacity of this new machine. So, they cannot facilitate the same diameter that this spindle has. Turning particularly long parts can be quite tricky and we have to get our parts ‘bang on’ with no taper or deviation, as many parts go for secondary grinding operations. The existing machines that we have, which are a lot older, have more wear and are not in line. This new machine is far more rigid and a lot more capable of machining longer parts, accurately.”
“Since we have been using the machine, we have had no scrap parts or errors and there is absolutely zero taper along the length of these parts. We have several relatively long workpieces and in some instances, we have not been able to take the work on as we could not do so. Effectively, we were losing out on business. By installing this new machine, we have been able to take on larger jobs and we have more capacity, as now we have an extra machine doing this type of work. The machine is also extremely reliable.”
The new LTC-35 Series turning centre has a 30kW spindle motor, a FANUC CNC unit with a capacity that can accommodate parts up to 2100mm with a maximum workpiece diameter of 600mm. With an X-axis travel of 344+10mm and a Z-axis of 1100mm, the machine can accommodate large parts whilst offering flexibility with its 12 tool station turret. There are additional variants with different dimensional capacities in the series.
Explaining the operations that are being undertaken on the new box slideway machine on a particular L43 steel part that is almost 1m in length, Robbie Beaman adds: “On this particular job, we have faced and centred one end, then turned and tapered the length of the component – with absolutely no vibration and much better surface finishes. We can absolutely rely on this machine for machining our components to a very high standard.”
“We also machine a lot of difficult materials that are difficult to chip, but the torque on the machine improves the cutting performance of the tools and allows you to run at higher feeds and speeds with improved cutting action,” concludes Robbie.

Breaking it down chip by chip

Five Things to Know About Chip Formation in Machining
Whether examining how tool selection is impacting chips, how coolant plays a role in chip evacuation or looking at the size and shape of chips, chip formation says a lot about the application. Knowing what different chip details indicate can allow machinists to better manage chip formation, make adjustments and prevent tool failure. When it comes down to it, better chip formation means a more successful application.

Shape & Size
When looking at chip formation, a key indicator of a good chip is the shape. The preferred outcome for any application is whether chips are shaped as sixes and nines or a single conical shape. These small, manageable chips are essential for efficient, predictable drilling. Nevertheless, it is important to be aware of what chips in other shapes and sizes can indicate. For example, a straight, flat chip is a result of elasticity. If the chip is a continuous ribbon, then it is likely that many adjustments need to be made chips.
The size of the chip impacts evacuation as well. Two major factors impact the size of chips in drilling tools: chip breakers and lip geometry. With chip breakers, the width of the chip is thinned to allow for easier evacuation; the wider the chip the easier it is to get it to roll onto itself and break. Lip geometry acts as a mechanical chip breaker to fracture a chip by curling the chip on top of itself or by impacting the chip forming with the back of the lip radius. Although harder materials will curl a chip on top of itself to create chip fracture, gummier materials often skip over the lip radius and only fracture after impacting the back of the lip radius. Still, the purpose of the combined chip breakers and positive lip geometry is to break off the chip so that it is narrow enough to easily evacuate.
Chip fracturing can also occur naturally due to the velocity differential between the outside and inside of a chip, which creates a cone-shaped chip that curls on itself and fractures. As large diameter inserts have a higher velocity differential than smaller inserts, it is easier to fracture chips, i.e. the larger the chip breaker spacing the more chip fracturing that will occur. Smaller diameter inserts are limited to the velocity differential available due to the restriction on the chip width required to easily evacuate chips through the holder gullet.

Thickness
The thickness of the chip varies with the feed rate; heavier feed rates form thicker chips while lighter feed rates form thinner chips. The thickness of the chip formed decides how the chip will fracture, but this is also dependent on the material being machined. At the same time, changing the speed impacts the chip thickness; the higher the speed of the tool, the more heat generated in the cut, which makes the material more elastic. So, a balance between speeds and feeds is necessary. With many materials, a thicker chip means there is a greater chance of exceeding the elastic limit of the materials, which increases the likelihood of chip fracture. On the other hand, thinner chips are more elastic and, thus, farther away from the elastic limit necessary to fracture the chip.
Soft, gummy materials like soft carbon steels, 300 series stainless steel or pure titanium have a high elastic limit. This means increasing chip thickness harms chip formation. Materials like these require specific lip geometries to potentially create an acceptable chip. Nevertheless, it is key to look at the chip deformation ratio of materials to better understand chip thickness. Chip deformation ratio can be defined as the ratio of deformed chip thickness over the undeformed chip thickness (feed rate). For most steels, this ratio is typically 2-3:1. However, it can be as high as 5-10:1 for those soft, gummy materials. Ultimately, though, this measurement is an indicator of chip form and elasticity in the material being cut, and the higher the deformation, the more difficult chip formation will be.

Coolant
When it comes to coolant, through-tool coolant is critical for the best chip formation and evacuation. Additionally, changing coolant type, pressure and volume influence the thermal shocking of chips. This can change the properties of the chips and make them more or less likely to break into manageable segments. For example, coolants can decrease material elasticity due to the strain hardening that occurs as coolant quickly cools hot, elastic chips. The cooling of elastic, continuous chip formation embrittles chips to the point of fracture by reducing their elastic limit.
For chip evacuation, coolant pressure and volume are important. To evacuate a set volume of chips, a set amount of kinetic energy is provided by the coolant volume. Drilling can occur uninterrupted from the top of the hole to the bottom as long as enough coolant volume is available, which will be evident during the application with a steady load meter reading while drilling. With an insufficient coolant volume, an unsteady load meter will be detected when drilling into the hole. Although this does not mean that drilling with insufficient coolant is not possible, it does demonstrate that the drill must be altered to fit the environment.
As coolant pressure is increased through a fixed coolant hole diameter, the coolant volume will increase. When drilling small diameters, high coolant pressure is needed to provide sufficient coolant volume, but as drill diameters increase, high coolant volume becomes more necessary than high coolant pressure. In high-production drilling—especially deep hole drilling—through the tool coolant is critical because it provides an upward force on the chip to aid in flushing the chips through the drill flutes. Although flood coolant can be used alternatively to through coolant in short drilling applications under 2XD, in deeper holes flood does not promote good heat transfer and can also push chips back into the hole, which can cause chip packing.
Through-tool coolant is also important when factoring in heat because it provides coolant right to the cutting edge where it is needed to cool the tool. When machining, 60% of the heat generated in the plastic deformation of the material remains with the chip formed while the other 40% remains with the tool and workpiece. This portion that stays with the tool must be evacuated by coolant to have sufficient tool life. When more coolant pressure and volume can go through the tool, the cooler the tool will run. This then means that there will be greater tool life and that the tool can potentially be run faster.

Tool Selection
Chip formation can also indicate whether the best tool is being used. If the chip formation is not meeting the standard, a change to tool geometry may be needed to improve the situation. The geometry of a cutting tool has a significant impact on the chip formed. Specifically, increases in rake angles can improve chip formation, yet this does come at a cost as it weakens the cutting edge.
Rake angle also influences the value of the shear plane angle, which is the angle formed by the pure plastic deformation of the workpiece material. Here, the material starts deforming or chip forming in front of the cutting edge. For both material properties and running parameters, the angle varies; however, it should always be a goal to make the shear plane angle more vertical because the steeper the shear plane the better the chip formation.
Chip thickness comes into play here as well. The more elastic material is the steeper the shear plane angle will be, resulting in a thinner chip. Conversely, the harder the material is, the flatter the shear plane angle will be, which means a thicker chip is formed. All in all, more rake angle means more shear angle, which means better chips, but balance is key. A sharp cutting edge will make great chips but will fail and break due to a smaller cutting edge cross-section and weaker cutting edge, so find balance in the rake angle—one that is aggressive but not overly so.

Changes in Chip Formation
A final thing to look for is any changes in chip formation. If chip formation is altered during an application, it could be caused by a myriad of elements: wear on the tool, built-up edge on the tool (BUE) or changes in the environment like coolant or material changes. In new applications, it may be best to drill shallow test holes and take a look at the chips to make sure they are small and segmented. Being conservative at the beginning with speeds and feeds could also aid in better understanding chip formation.
Awareness of any changes in chip formation is critical. Poor chip formation can cause major problems in drilling applications. Long, continuous chips are difficult to evacuate and can become packed in the drill flutes, damaging the drill or even causing drill failure. These long chips could also become wrapped around the drill body and cause tool failure. Lastly, poor chip formation impacts the hole quality. If chips are dragging or packing in the flutes, there will be a poor hole finish.
Knowing more about the chips formed in any metal cutting application enables machinists to better control the outcome and success of drilling operations. While it is necessary to examine chip size, shape and thickness, it is just as important to know how coolant, tool selection and changes in chip formation tie in with the application as well.

McDowell runs rings around aero rivals with NILES-SIMMONS

Founded in 1910, OTTO FUCHS Group is a world leader in the aerospace, automotive, construction industry and industrial engineering sectors. With more than 10,000 employees in subsidiaries around the world, the German manufacturer plays a key role in supporting OEMs with products and services of impeccable quality levels – this is why it has recently invested in a NILES-SIMMONS N50 MC turn-mill centre, which is available in the UK from McDowell Machining Technologies.
The OTTO FUCHS facility in Meinerzhagen specialises in producing billets, forgings, extrusions, ring-rolling products and machined parts from aluminium and titanium alloys for the aero industry. With over 5,000 products manufactured from almost 100 different alloys, OTTO FUCHS is an integral part of the international aerospace manufacturing sector.
To service its customers, the company needed an extremely capable machine tool with unparalleled flexibility and automation – the solution was NILES-SIMMONS N50 MC turn-mill centre with a Kuka robot for loading and unloading parts. The core of the project for OTTO FUCHS was to optimise and fully automate the machining of double, triple and quadruple engine rings for the aerospace sector.
Rene Casagrande, Segment Manager in the Aerospace Engine Disc Production Department at OTTO FUCHS, located in the North Rhine-Westphalia region says: “We manufacture engine discs for all the major manufacturers in the aerospace sector. The main focus is on titanium and nickel applications and this entails special applications in terms of our machining requirements. We have recently built a new production facility where the new NILES-SIMMONS N50 MC became an integral part of the plant. There was a requirement for a machine with double spindles to ultimately achieve production efficiency on titanium and nickel components.”
It is here that the NILES-SIMMONS N50 MC with the Kuka automation system perfectly suited the requirements of the aerospace manufacturer.
The NILES-SIMMONS N50 MC is built upon a modular concept that enables the end-user to select the technical specifications that suit their particular application. Typically, the N50 MC incorporates a main and counter-spindle, a distance between centres of 3000mm with a swing diameter of 1250mm and two tool magazines. With in-process tool and workpiece probing, a blank and finished part shuttle and a Smart Factory system for Industry 4.0 integration – the N50 MC can cater for the demands of any machine shop.
From a flexibility perspective, the modular concept behind the NILES-SIMMONS N50 MC allows customers like OTTO FUCHS to configure the machine to incorporate milling, turn/mill and 5-axis milling, deep hole drilling, ID machining with a boring quill, gear hobbing, grinding, process and condition monitoring and much more. It was this ability to build a flexible ‘production cell’ to its particular requirements with part loading and unloading with a Kuka robot solution plus the robust and productive platform that led OTTO FUCHS to NILES-SIMMONS.
Rene Casagrande adds: “Important aspects in our selection was the high cutting performance. In this case, we have to have a high level of automation, so we have complex automation practically from the double ring to the finished product. Equally important is traceability, the fact that there is automatic linking means that traceability is 100% from start to finish. This is a special feature in addition to the naturally high level of automation within the machine.”
At the facility, the company produces aluminium, magnesium, titanium and nickel alloy forgings up to 750kg and 5m in length, extrusions from 0.1 up to 25kg/m and rings for aircraft turbines from 300mm up to 2m in diameter and from 30mm up to 800mm high.
Casagrande summarises: “We chose NILES-SIMMONS because the machining of titanium and nickel components is very challenging and we were looking for a partner who could precisely meet all these requirements, especially in combination with the aerospace industry and its demands.”
“In retrospect, it has been a circular project from our side, from the beginning with the order placement through to project planning, construction and commissioning and through to today where production has been running for almost 12 months. Everything has been positive all around whether that is technologically or also regarding the optimisation of the systems. We continue to have the full support and great cooperation with NILES-SIMMONS and I can say that they are a very good partner in this respect,” concludes Casagrande.

‘Flawless’ performance matches engineering firm’s ambitions

When an engineering firm’s mantra is ‘no compromise on quality,’ it simply can’t afford inaccuracies. Addison Precision delivers bespoke precision components and assemblies to the aerospace, military transport and mining industries. Supplying advanced applications to clients across Europe for almost four decades, it has more than 100 full-time engineers and harbours ambitions for further growth. And that’s one of the reasons it turned to ZOLLER UK.
Don Hopper, Special Projects Manager at Blackpool-based Addison, explained: “Our customers expect parts to a schedule, right first time, every time. We’re measuring tolerances to microns. We started research into getting some pre-setting equipment so that we’d have the ability to measure the tools built into an assembly before putting them anywhere near a machine tool. The idea behind that is to check that everything is correct – we use a lot of PCD-type tools which, if you touch with metal, can be damaged, so a contactless measuring system is absolutely brilliant.”
Dedicated to tool pre-setting and inspection equipment, ZOLLER UK has best-in-class, intuitive and ergonomic technology to ensure tools are of the right quality to create accurate parts before machining. By introducing increased efficiency to their production cycles, businesses are guaranteed a rapid return on investment as well as a significant boost in reliability.
Addison opted for the ZOLLER Venturion 450; a system equipped for the shop floor. Mr Hopper said: “I would recommend the ZOLLER. Our experience has been flawless. All of our guys like the interface, they’re just amazed at what it’s capable of doing. The beauty of the machine is its power-clamping system. It’s interchangeable – you don’t need to mess around changing back-end adapters. The power-clamping unit drops in, you put whichever back end it is you want to check the tooling and away you go.”
“This has enabled us to have more accurate detail of what we’ve set. We’re measuring tool runout, which is very important on reamers, boring bars and things like that.”
Being safe in the knowledge that nothing has been left to chance with the Venturion 450 is proving invaluable for Addison. Mr Hopper said: “We’ve come up with a system where we measure the tools with the ZOLLER, we save that to a file on the network and that’s then downloaded directly into the machine control. So, there’s no manual operator input and that’s a big step forward.”

“It’s reassuring that you’ve checked everything because before with the lasers you could only check tool length and the biggest diameter without a lot of additional programming. With the ZOLLER, we put together a tool card which has details of the tool assembly in its entirety, so we’re not only measuring the cutting tool and the important surfaces on it – we can also check the holder it is in and ensure the correct diameter. That means it’s not likely to collide and it has the right amount of tool reach to clear all the obstacles on the machine while it’s in operation.”
According to Mr Hopper, the quality of customer service offered by ZOLLER UK from its base in Foston, near Derby, has also been second to none. He said: “ZOLLER came in, installed the equipment, moved it into position, made sure everything was correct, calibrated it and then we got a comprehensive two-day training package. It was very, very useful and very comprehensive.”
“When we’ve asked for help they’ve always been there – it’s just been great. We just pick the phone up or send an email and they get straight back to us. There’s never been an issue.”
“It was very fortunate that the owner of our business just happened to be on-site at the time during the ZOLLER demonstration. He looked over our shoulders at what was going on and was so impressed with it that he phoned up and negotiated the deal to purchase the equipment. Ultimately, the plan is to grow our business, so by adding additional machines there may come a time when we need to purchase more ZOLLER equipment, but at this moment in time, it copes with everything that we can throw at it.”

VERICUT and AML simplify complex machining demands

After a decade of using VERICUT machine simulation, verification and optimisation software, Advanced Manufacturing (Sheffield) Ltd (AML) is extolling the virtues of providing industry-leading protection for its high-value capital assets and expensive parts. VERICUT from CGTech is a key component of business success at this rapidly expanding precision machining company, which serves a plethora of customers in sectors such as aerospace, energy and defence. More recently, AML has embraced the efficiency and productivity gains offered by VERICUT’s Force™ module, which is driving tool life gains and cycle time reductions in the order of 30-40%.
Originally a spin-out from the award-winning Advanced Manufacturing Research Centre (AMRC) at the University of Sheffield, AML is today a recognised market leader in delivering flexible manufacturing capability at the leading edge of machining technologies and efficiencies. The company is AS9100-certified and carries a Rolls-Royce Certificate of Approval. In addition, AML is part of the SC21 framework for ’21st Century supply chains’ to accelerate the competitiveness of aerospace and defence companies.
To manufacture the market’s highest quality precision parts, the company utilises the very latest technologies, including VERICUT simulation, verification and optimisation software from CGTech.
“We’ve had VERICUT from day one of manufacturing at AML, which dates back around a decade,” explains Engineering Manager Jason Mills. “VERICUT is our safety net; it looks after our complex components, some of which are machined from expensive forgings that cost over £50,000 before we’ve even drilled a hole. There is no margin for error. We use all of the features in VERICUT, including gouge detection, collision detection and, more recently, the FORCE module. The software also looks after our machine tools through virtual simulations, which are critical because a replacement spindle could cost around £40,000 for the hardware alone.”
From receipt or generation of customer CAD, forging and stage models, AML engineers start building up what it calls the ‘Tech Pack’ from its Siemens NX CAM system, including documentation and any relevant paperwork. The company will then start importing the component, fixture and tool models into VERICUT. Here, AML can take advantage of its VERICUT NX Interface, a function that provides an easy and convenient way to verify, optimise and analyse individual NC programs, a series of selected tool paths or a complete sequence of operations, directly from within Siemens NX.
“We then start simulating the tool paths, checking for everything that could go wrong, from collisions and near misses, to spindles running in the wrong direction,” explains Jason Mills.
AML has seven seats of VERICUT base and essential modules that include Verification (detects program mistakes and verifies part accuracy), CNC Machine Simulation (detects collisions and near-misses between all components in the machining zone) and Multi-Axis (simulates multi-axis milling, turning and mill-turn operations).
The latter is vital as AML has 15 DMG MORI CNC machine tools on-site, almost all of which are high-specification, multi-axis NT series mill-turn models. These include a large NT6600 with a 6-metre bed and the latest arrival, an NT4250 DCG, which is capable of simultaneous five-axis mill-turn operations with a direct-drive motor installed on the B-axis.

“Business is extremely busy, so we also have a DMG MORI DMU 125 FD five-axis machining centre on order and are looking at two more assets shortly,” says Jason Mills. “We are not shy of investment if it makes sound business sense.”
The company also takes advantage of several further VERICUT modules, including AUTO-DIFF™, which compares a CAD design model with a VERICUT simulation to automatically detect differences, weaknesses or mistakes in the design.
“We use AUTO-DIFF on every component as part of our standard operating procedure [SOP],” states Jason Mills. “With AUTO-DIFF, anyone involved in the manufacturing process can identify an incorrectly processed job. We find that it often flags up errors, especially as we have numerous mill-turn machines. The tools on mill-turn machines can be flipped around either way, so if they are not set up correctly, VERICUT will capture it.”
Additional VERICUT modules on-site include CNC Machine Probing, which checks for probe collisions (all of the CNC machine tools at AML feature Renishaw probes), and TDM Systems, which provides a live, on-the-fly connection to TDM. The company is now building tools in TDM for direct import into VERICUT.

Most recently, AML has added Force – Milling to its list of modules. VERICUT Force makes optimising an NC program fast and easy by calculating the contact between the tool and material, cut-by-cut. Force also takes the cutting-tool edge and material into account, adjusting the feed rates accordingly so they are optimal and constant.
“We’ve seen up to 40% more tool life and 30-40% savings in machining cycle time when using VERICUT Force,” says Jason Mills. “The module is invaluable for our production work as it provides us with a competitive edge. It’s quite easy to use and understand. We simply pick the material from the database and input the cutter geometry, which we get from the tooling manufacturer. Force then does its calculations in the background.”
AML has come a long way since spinning out of the AMRC (the company remains a tier-two AMRC member to this day).
“We have 30,000 ft2 here now, which is a tenfold increase in 10 years,” explains Operations Director Mark Hands. “We’ve gone from 8 staff to 66; from two CNC machines to 15, and imminently about to sanction another two.”
It is all about continuous improvement at AML, a strategy that is spurring ambitious goals for the years ahead.
“For the 2021-2024 period we set targets to grow turnover from £4.9 million to £12 million; headcount from 55 to 110; and assets [CNC machine tools] from 10 to 22,” says Mark Hands.

AML is also working with a team of consultants from Sharing in Growth, business experts in the world of advanced manufacturing. The dedicated three-year transformation improvement programme is witnessing the entire AML team commit to an intense and comprehensive scheme of training, mentoring, coaching and development.
“We are big believers in reinvesting in our future, as well as our people,” says Mark Hands, who joined as a project engineer in 2011 and is now a company director and major shareholder. Similarly, engineering manager Jason Mills began his career at AML as a CNC machinist, while the company’s quality manager was originally a press brake operator.
The coming years are bright for this progressive manufacturing business, where production follows a simple mantra: apply the best manufacturing technology available to provide low-cost parts to customers. This is more than just a tagline; AML was born out of advanced research activities and the company still believes that technology is a key differentiator in providing value for customers. AML aims to apply the best knowledge in tooling, CAM strategies, dynamic analysis and CNC machine platforms to deliver precision quality at high production rates. The key to this goal is VERICUT.
“VERICUT brings security to our business,” says Mark Hands. “Not just because our parts are expensive, but because some are 1-offs with no margin for error. We also rely on VERICUT to protect our CNC machines; large, expensive assets that are costly to repair. If we’re not protecting our machines or our parts, then we’re not protecting the customer programme, nor the relationship we have with them. Right first time within the business is a must and VERICUT is a vital part of that.”
Jason Mills concludes: “I can’t ever see us changing from VERICUT. We’re comfortable and happy with the software, as well as the level of support we receive from CGTech. Today we apply VERICUT to all of our parts. No matter what we change in NX, even if we just add a command to turn on the coolant, it goes through VERICUT as it provides confidence for everyone in the business, from directors to machine operators. You can’t put a value on that.”

Automation raises productivity 25%

German subcontractor Euler Feinmechanik, based in Schöffengrund, north of Frankfurt, has invested in three robotic machine tending systems from Halter that are available in the UK through Salisbury-based 1st Machine Tool Accessories. The tending systems automate the loading and unloading of its DMG MORI lathes.
Established more than 60 years ago and with around 75 employees, Euler Feinmechanik machines complex turned and milled parts such as optical bearing mounts, medical and aerospace parts, housings and stators for vacuum pumps. Materials machined are mainly aluminium, brass, stainless steel and various plastics including PEEK, acetal and PTFE.
Managing Director Leonard Euler explained: “Our production processes include milling, but are centred mainly on CNC turning of prototypes, pre-production batches and series parts. We develop product-specific manufacturing strategies for our customers. For example, Airbus, Leica and Zeiss are supported from the development and production stages through to surface finishing and assembly.”
When Euler Feinmechanik bought a DMG MORI CTX beta 800 4A CNC turn-mill centre for complex components, the company knew it wanted to automate the machine, but first had to establish a reliable process. That was the responsibility of Marco Kühnl, the senior technician. He said: “We purchased our first loading robot in 2017 and it has allowed us to increase productivity while getting labour costs under control.”
Mr Euler added: “DMG MORI was in the running, as it had introduced its Robo2Go robot. This seemed to us to be the most logical combination and it is indeed a nice product, but it can only be programmed when the lathe is not running. However, Halter is a specialist in this field and not only had a good automation solution, but also great references and working demonstrations that showed exactly what we wanted. In the end, we opted for one of its Universal Premium 20 cells.”

There were various reasons for the decision, one of which was the use of high-quality components in the construction, such as a FANUC robot, Schunk grippers and a laser safety system from Sick. The mobile Universal Premium 20 can be moved quickly from one machine tool to service another, providing a high degree of production versatility on the shop floor.
The cell is designed for automatic loading of billets and unloading of machined workpieces to a maximum diameter of 270mm. A customer can choose from a large selection of grid plates of different capacities for buffer storage. To facilitate the connection of the loading robot to the CTX beta 800 4A, Halter equipped the machine with an automation interface.
After automating the machine with the Halter cell, productivity increased by about 25%. A year after purchasing the first DMG MORI turning centre and retrofitting it with automated loading and unloading, Euler Feinmechanik bought two more lathes, another CTX beta 800 4A and a smaller CLX 350 devoted to producing about 40 different components for the optical industry.
The two new machines were immediately equipped with Industry 4.0 compliant Halter loading robots identical to the first. Production on all three twin-spindle lathes can continue unattended for an average of half a shift, which maximises productivity and reduces labour costs.
Automation has improved production efficiency to such an extent that the subcontractor intends to continue automating its plant. A Halter LoadAssistant is planned for an existing DMG MORI lathe on the shop floor and asking Halter to add additional functions like workpiece polishing and grinding to the automation cells is being considered.

EROWA retrofit robot can deliver growth for the aerospace sector

The 2021 edition of PwC’s ‘Global Aerospace and Defense: Annual Industry Performance and Outlook’ shares key performance metrics of the global commercial aerospace and defence industry drawn from the 100 largest companies by revenue. With civil aircraft production set to ramp up and new challenges in the defence arena, the supply chain will need to keep pace. Here, an EROWA retrofit robot package can unleash previously untapped sources of productivity and profitability very quickly.

According to the report Boeing has more than 400 737 MAX aircraft in inventory to deliver and has stated plans to ramp up production of that model to 31 per month in 2022. Airbus also plans to increase production of A320s to 45 per month by the end of the year. The Biden administration looks to increase military spending, while Europe’s elevated levels of terror threat and continuing tensions with Russia mean defence budgets are expected to grow. The UK, Germany and France all confirmed their intention to reinforce their defence capabilities. However, this may not result in a large number of new programmes. Instead, the requirement will be to rapidly develop new intelligence and cyber capabilities.
Managing Director of REM Systems, UK and Eire agents for the Swiss automation specialist, Ian Holbeche, explains: “The long-term forecast for commercial aerospace appears very positive. Just consider, for example, that 82% of the global population has yet to set foot in an aircraft, and, with the global middle class projected to grow from 25% to 60% by 2030, there is an enormous untapped segment of new customers. This adds up to a significant increase in the delivery demands placed on the supply chain – our customers.”
He continues: “Retrofitting an EROWA robot to an existing lathe, machining centre, mill/turn or even a combination of these machines in a cell will allow any machine shop to operate effectively around the clock. And, you do not even have to pay for holidays, sickness, overtime or employee contributions, so the benefits quickly add up.”

For just a small investment an EROWA Robot Easy or Robot Compact 80 can achieve a very quick payback. Efficient productivity, flexibility and process reliability are more important than ever in these difficult times. Making the most of the available production time the business already has will keep any company competitive and ensure promised delivery schedules are achieved.
The EROWA Robot Easy 250 offers a small footprint, from only 3m². The Robot Compact 80 fits within a 2m² footprint and can lift to 80kg. Both robots are suitable for side and front loading installations making them flexible enough to fit into any available shopfloor space.
Everything required to ensure the automation system runs perfectly is included in the retrofit package. It comprises an Air Dock System that allows 5-axis machines without a compressed air supply for the chuck on the machine table to be reliably automated; a Robodoor for machines without an automatic door and the dimensions of the door are optimally adapted to suit the machine; and machine preparation of the interfaces between the machine and the handling robot which are configured to suit the application.
Automation training is also taken care of. After installation and setting up of the retrofit robot package, employees will receive comprehensive training in the correct use of the new automation system to ensure the business gains the expected benefits. Ongoing support will also be provided when required, such as when new staff are expected to support the automation.
An optional addition to the package is the EROWA JobManager JMS 4.0 ProductionLine, the universal production process control system for many machining operations. This practical online process control system provides automatic management of machines and loading robots. Within the overall concept of Industry 4.0, EROWA’s production process control system occupies an important position. It maps a large part of the functionalities that fall under the heading of ‘smart factory’.
This provides machine shops using chip-cutting production with significant advantages: it provides a clear view at all times of every workpiece being processed, their exact locations and how far into the process each is in real-time. It links up all the data and controls the entire production process. Its software connects machines with the widest variety of manufacturing technologies without any problems.

Ian Holbeche states: “By using automated loading, a machining centre typically runs much more economically. The hourly output increase by a factor of three or more. So, hourly machine rates can be reduced thereby improving competitiveness.”
Putting forward a simplified calculation that highlights the benefits of the retrofit robot package, he says: “If we compare a CNC machine tool investment of £300,000 against the additional investment of £85,000 required for the retrofit package. Without automation on a single shift with an operator, the machine has 1,500 available hours. The overhead cost will be around £80 per hour with an earning or charge out rate of £100 per hour, the payback period is around 6 years, with a 9% ROI.
“With the robotic automation and the same single shift operator, the machine’s available hours increase to 5,800 per year. This reduces the overhead cost to around £35 per hour and allows the business to reduce the charge out rate to £70 per hour, thereby increasing the competitiveness of the business. This results in a payback period of less than 2 years which equates to an ROI of over 80%.”
Of course, every application is different but exact calculations for any machine shop ROI can be provided by REM Systems’ experienced staff. As Ian Holbeche concludes: “Given the current extended waiting times for new machine tools, that could lead to capacity shortfalls that could be addressed by the EROWA retrofit robot package. Robotic automation also supports the current environmentally-conscious principles of making the most of what you have already got – effectively making more with less.”

Germany’s next top-model

Long before a new car model hits the streets, you could already touch it at MT Technologies – if everything were not so top secret. The model maker that existed before the car was invented, manufactures entire vehicles as a reference and tests models made of aluminium for numerous OEMs. What the experts produce with high machining performance from solid blocks, mostly in batch size, must first be clamped very efficiently. Thanks to the intelligent zero-point clamping technology from AMF, this can be done quickly, flexibly, with high repetition accuracy and process reliability using the modular principle.

“The impulse came from Formula 1,” says Mario Goth, remembering a visit in 2013 to the Sauber Team in Switzerland. The Manager of Mechanical Production at MT Technologies saw with astonishment how effectively the racing engineers clamped individual parts with AMF clamping technology. What the master model builder triggered in his own production operation has now grown into a continuous zero-point clamping system on all necessary machines. With Andreas Maier GmbH & Co. KG from Fellbach (AMF), the Ingolstadt-based company has a competent partner at its side that takes on the challenges of its customers and can offer customised solutions from standard products.

Clamping and set-up processes simplified
and accelerated
“At MT Technologies, they listened to us intently from the very start,” says Erik Laubengeiger from AMF, who provided customer support at the time. Their readiness was great to simplify the complex clamping operations of the aluminium ingots and significantly reduce the long setup and calibration times. “After all, most of the parts that we manufacture are small batches or individual parts of a maximum of four,” says Mario Goth.
When it is finished, the 1:1 scale model looks like a real car, but just made of aluminium. Even the doors and boot lid can be opened. It even sits on aluminium rims. And so the designers and engineers can make an initial three-dimensional image of a newly planned car model and walk around it. Attachment and cladding parts are also attached at the OEMs to verify the fits for subsequent series production. In addition, the clips in the aluminium model are already attached. The final aluminium model can later be found on the assembly line as a test and gauge model.

Small power packages securely grip
The raw aluminium blocks for the individual parts, such as the floor assembly, side parts, roof, boot lid and wheels must be manufactured with corresponding precision on the giant gantry milling machines and clamped precisely beforehand. Two work tables with dimensions of 1.3m by 2m and two with 1.3 by 1m as well as another one are used in the Jobs LinX machines. They are equipped with 50 or 20 K10 zero-point installation clamping modules from AMF at intervals of 200mm. “With the defined grid pitch, each work table offers us the greatest possible flexibility in positioning the elements”, assures Goth. And if a clamping point should be outside the grid or even outside the plate, that is not a big challenge. “With clamping rails, multiple clamping bars or other numerous clamping elements from AMF, we can reach every point that we need for safe clamping.”

The system is just as easy
and logical as Lego
The workers place modular spacer elements on top of each other on the work tables with integrated zero-point clamping modules and cross-T-slots until the block or the blank reaches the appropriate height, so that five-sided machining is possible. The clamping can be planned just as easily as a Lego building kit. The AMF range of connecting, construction and counterbalance elements as well as various adapters is almost inexhaustible. The upper interface to the workpiece is again a mechanical K10 zero-point clamping module, which positions and clamps the M8 or M10 pull-studs screwed into the workpiece in a process-reliable manner. “The system is just as easy and logical as Lego. Everything fits together and can be positioned quickly and precisely thanks to the zero-point clamping technology,” emphasises Christian Vogel from AMF, who is currently working with the Ingolstadt-based company.
The clamping modules in the work table are opened hydraulically at an operating pressure of 60 bar. Each one pulls in the correct pull-stud with 10kN and then holds it tightly with 25kN. Since the modules are intelligently designed and carefully manufactured, they can do this with a repetition accuracy and precision of less than 5µm. And since they are mechanically locked by spring force and tensioned without pressure, the pressure lines are removed after the clamping operation.

Collision-free 5-side machining thanks to
direct clamping
For direct clamping, the holes necessary for the pull studs are made directly in the unmachined part or aluminium block. The engineers already allow for that. To ensure that subsequent processing takes place without any interfering contours and is collision-free, AMF makes CAD data freely available in many common formats for all of its products. “This is an indispensable aid beforehand,” assures Vogel.
The cutting capacity is immense. This adds up to a processing time of up to 40 hours. A boot lid may be milled out of an aluminium block with an initial weight of 1.7 tons, which finally only weighs 90kg. All in all, aluminium blocks of various sizes, totalling around 20 tonnes, are required for a vehicle. It takes about five months for a vehicle to be finished in its original size. Since several spacious halls ensure the strict separation of individual projects from one another, the model-building experts at MT-Technologies can produce up to ten models a year.

Experience and craftsmanship for a 1:1 model
Finally, a new vehicle model in its original size stands in front of the observer long before it comes onto the road. For car manufacturers, this is an indispensable part of a new model’s development phase. And thanks to the experience in model construction and the manufacturing skills of the 150-year-old long-established company, the developers at MT-Technologies already know whether the car will meet their expectations at an early stage. Whether it will then be as classy as a Formula 1 racing car is not realistic, however.

Mitutoyo fixes bottleneck at Cox Powertrain

As a global metrology leader, Mitutoyo’s measuring equipment supported by the Mitutoyo Gauging Technology (MGT) division that can design, manufacture and install cost-effective, bespoke fixtures and loading systems – is a complete solution service that West Sussex based Cox Powertrain has recently taken advantage of.

In 2009, Cox Powertrain began its mission to deliver revolutionary ultra-lightweight diesel engines for the marine industry. The result was the design, development and build of the high-powered CXO300 diesel outboard engine. Having raised over £120m of private investment to bring the advanced outboard from concept to a reality and following EPA Tier 3, RCD II and IMO Tier II certification, Cox Powertrain began production of the CXO300 in May 2020.

To ensure efficient manufacture of the CXO300, Cox Powertrain built a world-class £6.7m production facility next to Brighton City Airport. Designed to deliver reliability and longevity, quality has been built into every facet of the CXO300. This all embracing quality philosophy is reflected in Cox Powertrain’s rigorous quality assurance systems. For instance, the company’s new factory was designed with a ‘no-fault-forward’ concept in mind. Each CXO300 component is fully traceable and continual checks are carried out at each stage of production to ensure that all parts adhere to specification before they move forward to subsequent workstations.

The recent installation of a Mitutoyo CRYSTA-Apex 9106 Series CMM, served by a tailor-made, highly-efficient loading and unloading fixture, reflects Cox Powertrain’s pursuit of the highest standards of quality and efficiency. The company’s advanced Mitutoyo CMM is equipped with a temperature compensation system that guarantees the accuracy of measurements under temperature conditions from 16 – 26°C. The CRYSTA-Apex temperature compensation system ensures that, in addition to having the ability to deliver accurate results, it is also able to undertake precise inspection routines within production environments, such as on Cox Powertrain’s shop-floor.

The highly efficient CRYSTA-Apex CMM offers a maximum drive speed of 519mm/s and a maximum acceleration of 2,309mm/s². As these impressive figures are much faster than those of general-purpose CNC CMMs, CRYSTA-Apex machines are ideal for operating within high-volume production and inspection situations.

Given the large volumes of components that need to be inspected on the company’s Mitutoyo CMM, Cox Powertrain Manufacturing Engineering Manager, Tom Wheeler contacted Mitutoyo Gauging Technology (MGT) with a list of system requirements related to a proposed bespoke fixture that would enable parts to be easily and quickly loaded and unloaded to and from the CRYSTA-Apex CMM. 

The MGT division of Mitutoyo UK provides a specialist service that aims to meet the increasing need for customised measurement solutions to support manufacturers’ quality assurance operations. From one-off fixtures to fully automated measurement systems, MGT can provide an answer to the simplest or the most complicated of measurement challenges. The outcome of the discussions between Tom Wheeler and the staff of MGT was the design of a loading/unloading fixture that would increase the efficiency of Cox Powertrain’s CMM.

Tom Wheeler explained: “Having considered other options, we decided the Mitutoyo CRYSTA-Apex CMM was the kind of high specification machine that had the ability to accurately and rapidly inspect our components, including those with the most demanding of dimensional tolerances. To ensure the rapid feed-back of inspection data to our assembly operations and to minimise scrap and rework levels, our new facility was designed using a highly-efficient ‘no-fault-forward’ model. Our Mitutoyo CRYSTA-Apex CMM and its bespoke loading fixture fit perfectly into this concept.” 

“As it has a temperature compensation system that guarantees high-precision inspection results under shop-floor conditions, we were able to locate the CRYSTA-Apex close to our assembly lines. In addition, the CMM’s high levels of automation, speed of operation and its rapid data generating capabilities means that, if a component dimension is found to be drifting from its nominal condition, prompt interventions can be made. To further enhance the CMM’s levels of automation and efficiency, we liaised closely with the MGT staff to develop an optimal design for a bespoke loading and unloading fixture. The result was the installation of a fixture that allows multiple components to be measured within a single cycle. The fixture has significantly improved our CMM loading/unloading speeds and efficiency levels. The combination of our highly efficient CRYSTA-Apex CMM and its bespoke fixture has proven ideal for our high-precision, high-volume needs.”

Pioneering tech firm helps NHS reduce carbon emissions

B

ritish smart MedTech company NeedleSmart is at the forefront of helping the NHS radically reduce CO2 emissions in its clinical waste disposal by a staggering 95% as part of its Carbon Reduction Strategy, saving tens of millions of pounds in clinical waste destruction.   

NeedleSmart is collaborating with the NHS, facilitated through the NHS Supply Chain innovation route, to drive a campaign forward to minimise single-use plastics and associated packaging. As of 1st April, and as part of the Government’s recycling policies, all plastic packaging must contain 30% recycled material or be subject to a levy of £200 per tonne.

The NeedleSmart technology is also part of an innovative programme to reduce and eradicate 100,000 needlestick injuries (NSI), which affect all healthcare workers across the NHS. This initiative alone will help save the NHS and its trusts more than £127m each year.  

The Knowsley-based company has designed and developed a range of products, including the NeedleSmart Pro (NS PRO) a world-first in safe needle destruction and disposal. The ground-breaking technology is being pioneered in a partnership with the Innovation Centre at Alder Hey Children’s Hospital and piloted with a number of NHS trusts across England as part of the NHS’s carbon reduction and sustainability programme.

As of 5th January 2022, the global Covid-19 vaccinations programme had delivered 134 million vaccinations in the United Kingdom, 513 million in the USA and 1.4 billion in India. In the UK alone, using the NeedleSmart technology purely in relation to the vaccination programme would have saved the NHS 15,132 tonnes of CO2 annually. This is equivalent to 15,000 flights from London to New York,  66m miles in a family car or  45,000sq/m of polar ice caps melting.

NS PRO destroys a contaminated hypodermic needle in a sealed chamber in just six seconds. The NeedleSmart device heats the needles inserted into the chamber to 1,300 degrees Celsius to kill potentially harmful pathogens, viruses and bacteria adhering to the needle. Within seconds, the needle is compressed into a tiny cold ball and released from the NS PRO device as a safe sphere of metal at the tip of the syringe. 

This not only safely destroys the needles, converting them into safe clinical waste and allowing for recycling, but also hugely decreases the amount and level of clinical waste disposal, along with the huge carbon emissions associated with disposing of that clinical waste and its incineration. Previously, the entire needle would have had to be disposed into a plastic sharps box, which carried a limit on how many intact needles could be disposed of. 

Now the clinical waste can be split into two parts, with the molten metal ball part of the clinical waste recycled as safe waste and the plastics recycled into the system. This represents a huge advancement for the NHS – which is one of the UK’s biggest producers of carbon – in reducing its carbon emissions and recycling its clinical waste.

NeedleSmart CEO and smart MedTech disruptor, Cliff Kirby said: “By adopting the NS PRO device, the NHS will enjoy a whole host of efficiencies in cost-savings and reduction in carbon emissions, in addition to crucial safety aspects. Using the NS PRO for the safe disposal of hypodermic needles can radically reduce the 100,000 needlestick injuries that occur each year to surgeons, doctors, clinical staff and hospital porters. But the even greater capability for reducing carbon emissions lies in the fact that using the technology means we can reduce the carbon emissions that the NHS produces by 95%.”  

 Claire Liddy, Managing Director of Innovation at Alder Hey Children’s NHS Foundation Trust, said: “The technology presents lots of opportunities for us to reduce waste and carbon, which is a huge agenda for the NHS and Alder Hey as part of the NHS Carbon Reduction programme. We want to be a hospital that is pioneering in the space of green tech. We think the NHS has a long way to go in the clean, green agenda, but we see the relationship between Alder Hey and NeedleSmart as being a great platform to achieve this as we work towards carbon net-zero.” 

UNITED GRINDING to present World Firsts at GrindingHub

The UNITED GRINDING Group will be presenting its C.O.R.E. innovation for the first time at a German trade show from the 17th to 20th May. The unveiling presentation, scheduled for 10am on the first day of the GrindingHub 2022 trade show will also include other innovations.

The UNITED GRINDING Group, a leading manufacturer of machines for grinding, eroding, lasering, measuring and combination machining is presenting its C.O.R.E. (Customer-Oriented REvolution) innovation at GrindingHub. Visitors can look forward to this and other innovations from the group, to be presented to all guests at the Group’s booth at an unveiling presentation on the first day of the show. 

With the initial presentation of C.O.R.E. at EMO 2021 in Milan, UNITED GRINDING Group launched a revolution in machine tool development. The modern hardware and software architecture at the heart of C.O.R.E. offers a visionary new machine interaction concept. C.O.R.E now opens up new possibilities for networking, controlling, and monitoring the production process, and thus for process optimisation. It also lays the foundations for the operation of modern IoT applications and the digital future.

The Group will also be presenting new products from its various brands, including MÄGERLE, BLOHM, JUNG, STUDER, SCHAUDT, MIKROSA, WALTER, EWAG and IRPD. Among them is the WALTER HELITRONIC G 200, the latest addition to the tool grinding machine range, featuring machine concepts on a mounting area of less than 2.3m². Other brands, including STUDER from the cylindrical grinding machines technology group will also be presenting world firsts. To keep things exciting, the company will not divulge any details about these new products in advance of the unveiling presentation on the first day of the trade show. 

UNITED GRINDING Group has selected the inaugural GrindingHub as the ideal stage for unveiling several of its innovations. The new trade show will also be the only German trade show at which the Group will be exhibiting this year. Stephan Nell, CEO of the UNITED GRINDING Group, has high expectations for GrindingHub: “We welcome the merger of three strong and experienced partners in the world of trade shows: the VDW, Messe Stuttgart and Swissmem. Given the strong international orientation of the trade show, we are convinced that it has the potential to become the new leading trade show for grinding technology.”

Sempre enters Renishaw partnership

Metrology provider The Sempre Group has been appointed to Renishaw’s Channel Partner Programme to help original equipment manufacturers (OEMs) access high-quality co-ordinate measuring machine (CMM) and gauging systems. By becoming a Premium Partner for the UK and Ireland, Sempre can now support OEMs and end users in the aerospace, automotive and medical industries by supplying Renishaw’s leading measurement systems and technologies.  

After a challenging two years for manufacturing supply chains, the benefits of localised support and speedy product supply for customers is clear. Renishaw launched its Channel Partner Programme in 2021 to help enhance local customer service and product support throughout the EMEA sales region. Within the programme, new partners are appointed based on their sector-specific experience and expertise in different metrology and manufacturing disciplines. 

As a Premium Partner, The Sempre Group will now have reseller access to Renishaw’s product portfolio, including the PH20 5-axis touch-trigger system, the Equator™ gauging system and the REVO® 5-axis measurement system. This uses synchronised motion and five-axis measurement technology to minimise the dynamic effects of CMM motion at ultra-high measurement speeds. 

“The Sempre Group has made several steps to better serve its UK and Irish customers — we’ve launched new products and services, as well as opened a dedicated Irish facility in County Dublin,” explained Jim Mangan, Managing Director of The Sempre Group. “Becoming a premium partner is a real endorsement of our team — Renishaw carefully selects its partners based on expertise and knowledge of particular regions, something that we hold in very high esteem. We are now in an even stronger position to provide ‘on-the-ground’ support and a high-quality product offering, giving manufacturers a competitive edge in the global market.”

“Its significant presence in the automotive and medical device markets, and its new local sales and demonstration centre in Dublin, Ireland, makes The Sempre Group a strong channel partner,” explained Jonathan Archer, General Manager EMEA North at Renishaw. “This partnership enables Renishaw to target these markets with its innovative products and solutions and both companies will collaborate further on providing training and support, benefitting our mutual customer base.”

MACH was ‘a huge success’ for Unison

MACH 2022 was an unprecedented success for Unison Ltd – the inventors of all-electric tube manipulation, and for its sister company Ingenium Integration Ltd – the exclusive UK and Ireland distributors of European-built Nukon fibre laser cutting machines. 

During the event, Unison sold one of its newly launched Synergy hybrid multi-stack tube bending machines, while Ingenium Integration sold two Nukon fibre laser machines. Between them, Unison and Ingenium Integration secured just short of 200 serious enquiries at MACH 2022.

“It was wonderful to be able to exhibit our world-class technologies at MACH once again,” comments Unison joint Managing Director, Alan Pickering. “With significant performance enhancements to our Breeze range of all-electric tube manipulation machines, we had an awful lot to catch the attention of visitors. Talking to prospective customers during the show, we gained the clear impression that confidence is back in manufacturing and that companies of all sizes are ready to invest in the machine tools and technologies that will help them achieve their goals.”

Such was the success of Unison’s attendance at MACH 2022, the company has already booked its space at MACH 2024. “Rather than having two stands – one for Unison and one for Ingenium Integration with Nukon – as we did this year, we will be bringing all our technologies together on one much larger stand in two years’ time,” adds Alan Pickering.

Dugard takes orders at show

Dugard Machine Tools won several orders and took a high number of enquiries at MACH 2022. With four new machine tools on its stand, the crowds were impressed by the breadth and diversity of the technology on show.

It was a MACH debut and the first opportunity for Dugard to introduce the Kitamura range since being announced as the UK agents. To introduce the brand, Dugard demonstrated the MedCenter5AX 5-axis vertical machining centre for fast precise machining and the larger Kitamura Mytrunnion 4G machining centre. As well as these two workhorses, Dugard gave a MACH show debut to the Hanwha brand of sliding head lathe that has taken the market by storm since entering the UK just over two years ago. Presenting the robust Hanwha XE20 and XD26II-V, the turned parts community paid attention to these newcomers.

Commenting upon the MACH show, Dugard’s Sales Director, Colin Thomson says: “We had representatives from Hanwha, Kitamura, Ibarmia and SMEC on the stand to support the Dugard team and throughout the week both our UK sales and technical teams and our technical partners from overseas had some very constructive conversations that resulted in several machine sales. Equally encouraging is the level of interest and direction that some of these meetings took at MACH, we fully expect to generate several additional sales in the months following the show. Aside from the success Dugard enjoyed, and the subsequent success that will follow, it was a pleasure to be back at MACH on a human level. No level of marketing activity can exceed the anticipation and buzz that MACH creates in the marketplace. It was great to be back and we are already planning a larger stand space for MACH 2024,” concludes Colin.

Automation stacks up for REM Systems

At MACH, REM Systems had the Erowa Robot Compact 80 as the centrepiece of its stand, using the technology as a demonstration cell to show visitors the business benefits from investing in Erowa machine tool automation. 

The Erowa Robot Compact 80 offers the optimal ratio between a large number of magazine positions and a small amount of floor space. The tall and lean design of the robot is suitable for optimal floor space use in the workshop and with a transfer weight capacity of up to 80kg, it can serve one or two machine tools. This was demonstrated at MACH and with more manufacturers paying attention to the flexibility and autonomy of automation, the system certainly won the attention of show visitors. 

Hexagon measured up at MACH

Hexagon’s Manufacturing Intelligence division presented its complete software portfolio at MACH 2022 to demonstrate how its easy-to-use solutions help engineering, production, and quality teams adapt more quickly to changing requirements and improve productivity from design to production and inspection.

Making their debut appearance at MACH 2022 was Hexagon’s computer-aided engineering (CAE) team that demonstrated how virtual manufacturing and costing solutions, such as the Simufact portfolio, predict defects and process challenges for cold rolling, sheet-metal forming, welding, riveting, and additive manufacturing operations.

Also on show was the Absolute Tracker that provides absolute positioning, so it can be detached from a measuring arm to scan anything using walk-around inspection. This handheld scanning flexibility makes it possible to scan large parts in-situ with high accuracy and surface coverage. 

Hexagon’s production software suite at MACH demonstrated robust, time-saving tools for all kinds of metal cutting, including solutions dedicated to sheetmetal workflow management and manufacturing, as well as mould production and additive processes. Demonstrations of the latest developments from EDGECAM, WORKNC, NCSIMUL and also ESPRIT that are all now integral to the Hexagon portfolio were particularly well received at MACH.

At the heart of the stand, Hexagon demonstrated its GLOBAL S coordinate measurement machine (CMM) that showcased a range of inspection activities that offer manufacturers the flexibility to adapt to many new requirements with a single machine. The CMM enables automatic switching between a growing number of different tactile and non-contact sensors. The latest of these is the ground-breaking HP-L-10.10 laser sensor, which enables manufacturers to perform non-contact measurements of almost any surface with accuracy comparable to that of tactile probes in a fraction of the time.

GM Group has victorious time at MACH

The debut appearance of the GM Group at MACH could only be described as a resounding success. For the GM Group, MACH was the perfect opportunity to present the merits of the Victor machines against its rivals. Anyone that has ever bought a Victor machine can guess what show visitors said about the range in comparison to other machines at MACH – the Victor is better built, more sturdy, rigid and robust with in-built technology that leaves other brands way behind. 

The GM Group presented the Victor Vturn-A20YCM and the Vturn-S26/60CM single spindle turning centres as well as the compact Vcenter-P76 machining centre – all three were extremely well received with several machine sales and some very serious enquiries being taken for all three machines. 

Commenting upon the debut appearance at MACH, GM Group Director, Nicola Howard said: “As a first time MACH exhibitor, we didn’t necessarily expect to sell machines off the stand – but we did! The Victor brand has been well respected in machine shops nationwide for decades due to its build quality and longevity, and the feedback we repeatedly had from show visitors is how delighted they were to see the re-emergence of the Victor brand in the UK. Our attendance at MACH has certainly elevated the Victor profile and this event may have helped awaken a sleeping giant. We had so many visitors show their delight that Victor machines are being sold once again in the UK with a proactive business that has a complete service, spares and support structure with a new showroom and training facility under construction. We’ll definitely be re-booking for MACH 2024 as this show has given us a debut to remember.”

XYZ is music to the ears of Rega Research

Southend-based Rega Research has applied engineering as the basis for the design and manufacture of its home audio systems for almost 50 years. Employing engineering to produce the best music for its customers has led to innovative designs that are both aesthetically pleasing and produce the highest sound quality. This combination has created a loyal customer base, with the past two years seeing significant sales growth, which resulted in its latest investment in an XYZ 750 LR vertical machining centre.

Rega Research was founded by Roy Gandy, who struggled to find an audio system that met his expectations. He was advised to ‘build his own’ if he couldn’t find what he wanted and the rest is history. Using his engineering skills gained in the automotive sector Roy’s re-engineering journey to create new concepts in audio began. The company now designs and assembles a full range of home audio equipment including turntables, amplifiers, phono stages, CD players, tonearms, cartridges and speakers. Production stands at over 5000 turntables every month made up of 3000 units/month of its entry-level P1 turntable, over 1000/month of its mid-range P3 turntable and 70 units/month of its range topping P10 turntable, which retails at around £5000. Add these to its other products and production tops 10,000 units/month. 

There is a subtle difference between music lovers and Hi-Fi enthusiasts and Rega’s products appeal to the former: “Our customers love music, many would go to concerts daily if possible, so we strive to deliver a level of quality that can replicate that experience for them,” says Ky Gandy, Supplier Co-ordinator, Rega Research. The blend of high quality, design and value for money has seen Rega grow from 130 employees at the start of 2020, with a turnover of £13m to a £20m turnover and 180 employees at the end of 2021. 

This significant growth added pressure to Rega’s Toolroom, which was populated with manual machines to produce assembly jigs and test rigs, as well as some prototype machining. A move to CNC had been on the cards for many years, but had been put off for several reasons, particularly a lack of space. A re-organisation combined by the increase workload allowed the purchase of an XYZ 750 LR VMC to go ahead. The machine will be used on a variety of materials from aluminium, High Pressure Laminate through to MDF, so Rega opted for the 12,000 revs/min model and a 4th axis with 24 position arm-type toolchanger option. 

“We had been looking at introducing CNC to our toolroom for several years, we did our research and while the machine was important, ongoing support and service was a priority. This resulted in a shortlist of one, XYZ Machine Tools. During our search, we kept coming back to XYZ and in the end, it became a straightforward choice due to the confidence we had in their ability to support us with technical help and after-sales. We also received glowing reviews from our existing component suppliers. Another factor that made the decision easier was that during the quotation process they didn’t try to upsell to us, we indicated an interest in their HD machines, but they did the right thing and sold us the machine we needed, not what we thought we wanted.” 

 Throughout the pandemic, focus was on delivering products to meet demand, so product releases were put on hold. Now, with a degree of normality returning, new products are on the horizon with new turntables and amplifiers due to be launched in 2022. This will see an increased workload for the XYZ 750 LR in terms of machining development parts and the testing fixtures that will also be needed. Having the machine will enable Rega to respond quickly to change and to meet the increased demand from its assembly department, where demand for fixturing continues to grow. There are no plans for the XYZ 750 LR to be used for production work, but it is filling a need for re-working existing stock components that may need rectifying or adjusting. A recent example was a batch of plinths that were found to be out of concentricity tolerance on two bores. “The obvious solution was to return the entire batch to our supplier, but that isn’t the Rega way of doing things,” says Ky Gandy. “We respect our suppliers and accept that occasionally errors arise, so we decided to rectify the parts ourselves. We used the XYZ 750 LR to manufacture a fixture, which was then able rework the parts to within microns. Something that saved time and money thanks to the efficiency of the machine and the input from Dan Ware, who joined us specifically to run the XYZ machine.”

HAAS improves cycle times by 40%

Trust is the key component to Redman Engineering’s relationship with its customers. Working closely with clients to achieve a true partnership has built respect over 45 years in business. “We grow as our customers grow”, explains Managing Director Bill Redman. “For many of our customers, intellectual property is a critical asset to their business. We machine every component in-house, which gives confidence in two ways: quality of the finished product and confidentiality of the manufacturing process.”

Originally an aerospace manufacturer, when Bill took over from his father in the 90’s the Essex-based company moved to making mechanical parts for the bio-chemistry and optoelectronics. Redman Engineering is now in these leading-edge market technologies.

 “Our involvement begins once the customer has established a concept and parameters for the product. From here, we have input concerning the mechanical aspects within their multi-disciplined team. Upon completion of prototypes and testing, production batches typically range from 5 to 40.  It’s very intricate and demanding work at times. For example, we recently produced the mechanical components for a high-speed camera capable of capturing images of a projectile fired from a barrel. The incredible detail provided goes as far as showing the surrounding shock waves.

 “It’s important for us to have the necessary kit to handle the job as efficiently as possible. The HAAS machine fits the bill admirably.”

Redman Engineering recently took delivery of a new VF-2SS Super Speed vertical machining centre, part exchanging their existing 18-year-old HAAS VF-2 as part of the deal. The VF-2SS has a 12,000rpm spindle, 30+1 high speed side mount tool changer and was equipped with a 210mm rotary table for full 4th-axis operation. “We’ve found cycle times have improved by 40% already and we’re still experimenting with some jobs, so we’re expecting that figure to rise. The machine is noticeably faster and more responsive. Our manufacturing team have over 150 years’ experience between them, and they really rate the HAAS. They are very comfortable with the machine. We use FeatureCam and OneCNC for our CAD designs. We do a lot of off-line programming and because we have the VF-2SS we can jump straight on the machine and start cutting.”

Redman Engineering also made the decision to invest in the HAAS wireless probing system. “We’ve found it very useful. It allows us to easily set work and tool offsets, it confirms parts are loaded correctly, and it inspects parts in-process on the machine. Our consistency though good, has significantly reduced the level of monitoring as parts come off,” explains Bill.

 “You get a lot of well thought out accessories as standard with HAAS. We didn’t use things like fixturing and air blast at first, but we’ve found out how useful they are as we’ve got going. When we began looking for a new machine we found that the HAAS website gave us precisely what we needed to know. This gave them a real edge as we didn’t have to keep calling; the information was all there. Then when we wanted to order, the process was quick and easy, including part exchanging our existing machine. The whole process was well controlled; it inspired our confidence, which is just how we like to work with our own customers.” 

 “We had one day on-site training to cover the new features and that’s all we needed. One of our operators hadn’t programmed a machine before, but he was able to start programming by the end of the day. Our guys really like the HAAS ‘Tip of the Day’ videos on YouTube and any queries we have can often be answered online. If not, then a quick phone call does the job. It’s all very accessible. HAAS really makes you feel valued as a customer and part of something much bigger.”

Guhring cuts through crowds with quality

MACH was a phenomenal success for Guhring with its stand being busy from the very start of the show to the point when the last visitors were leaving on Friday afternoon. The stand was hectic from the word go for several reasons. Firstly, Guhring demonstrated a complete range of products that included threading, turning, drilling and milling tools – many of which received their UK exhibition premiere at the show. The other reason was due to the tools being demonstrated ‘live’ on a GROB 5-axis machining centre.

Guhring gave a MACH show debut to the new RF100 Sharp Series of end mills that were put through their paces on the GROB machine. Designed to address the issue of machining soft, tough and high-alloyed materials that create an issue with swarf clearance, the new RF100 Sharp Series is Guhring’s sharpest solid carbide milling tool to date. Alongside the Sharp was the Diver Series of end mills that Guhring recently extended for micromachining with the new RF100 Micro Diver. 

Guhring had its holemaking ranges performing on the machining centre at MACH. With many of its industry-leading drilling lines undertaking ‘live cutting’ demonstrations, it was the RT 100T solid carbide spiral flute deep-hole drills that captured the imagination of engineers at the show. 

Commenting upon the exhibition, Guhring UK Managing Director, Chris Weston said: “Before MACH, expectations may have been somewhat subdued due to the unpredictable Covid situation, but that dissipated on day one with a very high number of enquiries – and this continued to surge throughout the week to give us our busiest MACH week ever. The enquiries we received were well balanced across our portfolio of products. We had technical engineers giving demonstrations of our vending solutions all week whilst the GROB G550 5-axis machine provided live demos of our deep hole drilling line and the new Sharp end mills to name a few. We have always alluded to the performance of our industry-leading lines that can achieve cutting parameters beyond alternate lines. This is especially true of our deep hole drilling range – but it wasn’t until engineers watched it on the GROB machine that they believed it.”

“It was the first time for Guhring to have a machining centre on the MACH stand to demonstrate products, and it worked extremely well. We had a crowd around the machine all week, paying close attention to the jaw-dropping performance of our tools. We are also delighted to announce that our cooperation with GROB at MACH was just the first step in a long-term partnership that has now seen Guhring UK take the impressive 5-axis machine that straddled both stands at MACH straight to the Guhring technical centre in Birmingham. Arriving at Guhring UK immediately after the show, the machine will cement our relationship and enable us to provide comprehensive demonstrations of our product lines on an extremely capable 5-axis machining centre. It will also serve as a facility for GROB to invite its customers to undertake machining trials,” concludes Chris.

MACH beats all expectations for XYZ

As March 2022 drew to a close, XYZ Machine Tools recorded its best ever month with a sales order intake of £3.4m. This figure was a pleasant surprise as with MACH just around the corner, it was assumed that customers would wait to make a purchase at the long awaited exhibition.

“We had little idea of how MACH would go, with people still anxious about Covid. The level of sales in March made us think that attendance at the show may be poor, with people ordering machines instead of visiting the show. How wrong we were,” says Nigel Atherton, Managing Director, XYZ Machine Tools. “From day one of MACH our stand was busy and the level of enquiries, and new orders resulting from the week are very encouraging and indicate that April will be an even better month than March.”

By the end of the exhibition XYZ Machine Tools had recorded almost 500 leads, 100 of which were described as hot, of which 32 have already placed orders, another 192 customers indicated they would be placing orders in the next 2-3 months, with a further 162 suggesting a six month lag to placing an order. New orders that can be directly attributed to MACH 2022 currently stand at 37 machines from 32 customers, made up of a mix of three manual machines, 20 ProtoTRAK controlled mills and lathes, and 14 Siemens controlled machines, a mix of vertical machining centres, turning centres and five-axis machining centres. The value of these sales is in excess of £2.4m.

“With these sales and ongoing negotiations, we are extremely happy with our attendance at MACH and a bonus was that even with our existing database of engineering companies, which extends to over 20000 names, we still managed to have conversations with 32 companies that we hadn’t come across before. Also reassuring is that our current levels of business are exceeding pre-Covid levels and there is little sign of buying confidence slowing down.”

Allied sports a new theme

The Allied Machine & Engineering stand at MACH was a sight to behold and the envy of its surrounding exhibitors. The sports bar theme was a huge success with MACH visitors, and the welcoming surrounding soon had the crowds flocking. 

Once on the stand, visitors were engrossed in the latest innovations from the manufacturer of holemaking and finishing tools. A centrepiece attraction of the show for Allied was the expansion of the T-A Pro high-penetration drilling system and the High-Speed Steel geometry insert that is also referred to as the ‘X’ geometry. The Super Cobalt insert works as a diverse drill insert while significantly lowering the risk for high-value components. When functioning in less than ideal conditions, the High-Speed Steel geometry provides superior performance and chip formation in addition to process security when needed most. 

With a tool life that rivals carbide, the HSS geometry insert works well in almost every material class and at MACH, Allied Machine’s team of engineers showcased this insert as the simplest solution for selecting a drill insert when hole quality, tool life and process security are the primary needs of the application.

Ceratizit reports best MACH ever!

Ceratizit UK & Ireland recorded the best MACH in the company’s history with enquiries, orders and positivity, all at very high levels. The Ceratizit stand at MACH was a major draw for many visitors with numerous cutting tool innovations on show and the opportunity to discuss specific requirements with any of the 40 plus technical engineers that the company had in attendance throughout the week. 

“Before the doors opened for MACH there was an air or uncertainty, but that was quickly dispelled as visitor numbers increased daily throughout the week,” says Tony Pennington, Managing Director, Ceratizit UK & Ireland. “Of course, there were concerns from customers, with many faced with common challenges of energy prices and raw material supply and costs, but the vast majority were reporting strong order books and a commitment to invest in the latest technology. Many accepted that there will be some peaks and troughs, but in general the consensus was that the next few years look extremely promising.”

For Ceratizit UK & Ireland this translated into a record number of enquiries with over 1500 requests for information or visits logged over the week. One key area of interest was that of coordination and security of supply of cutting tools. Here Ceratizit UK & Ireland provided the answer with its vending system TOM 840. With capacity to store up to 840 individual tools the system is supplied free of charge to customers with a minimum monthly spend of £3000, with the TOM 840 unit communicating directly with Ceratizit to maintain stocking levels of key cutters and inserts. 

“Tool vending is becoming ever more popular and at MACH we saw the interest in what our system can bring to customers increase dramatically. As a result of enquiries at the show we have ordered an additional 20 TOM 840 units, doubling what we already had on order. These will join the 500 plus units already out with customers,” says Tony Pennington.  

It wasn’t all about tools on the Ceratizit UK & Ireland stand as the British Heart Foundation and Cancer Research UK also benefitted from the raffle of a Hope HB 130 mountain bike, with the winning entry being drawn by World and Olympic cycling champion Katie Archibald MBE. The lucky recipient, who will take delivery of the £6000 bike once it has been custom fitted to his dimensions by Hope Technology, is Dave Buchan from Havant-based Monolution a specialist subcontract machining business focussing on top level motorsports and aerospace work. 

Floyd plays it cool

Now available from Floyd Automatic Tooling is the latest cutting tool innovation from Mikron Tool. The new CrazyMill Cool P&S square and corner radius series of end mill is a new 3-flute tool with patented coolant supply ducts integrated into the shank – a feature that Mikron Tool has developed specifically for rough and finish milling of stainless steels, titanium and aluminium based superalloys and also nickel-chromium based superalloys.

The versatility and geometry of the new CrazyMill Cool P&S also make it very well adapted for application on materials such as steels to 40HRc, cast iron, non-ferrous metals and plastics. Based on its ability to plunge vertically to 1XD and ramp at 45-degree angles, the new CrazyMill Cool P&S becomes a ‘plunge-mill’ capable of milling and drilling applications, making it especially suitable for milling grooves, pockets, face and side milling in the smallest of spaces as well as linear ramp milling. 

The end mills are available in diameters from 1 to 3mm in 0.1mm increments and up to 8mm with imperial dimensions also available. The impressive new series is available as a Type A and Type C variant. The Type A end mills are manufactured with an optimised 2.5XD geometry for robust machining of challenging materials and high material removal rates. The Type C end mills provide a 5XD geometry for reaching into cavities and machining complex profiles. The 2.5XD end mills are supplied with a corner radius from 0.1 to 1.5mm depending upon the diameter selected and the range has a shank diameter from 4 to 12mm with an overall length from 40 to 70mm with an effective flute length from 2.5 to 20mm. In comparison, the longer 5XD variant is also offered with 0.1 to 1.5mm corner rads with shank diameters from 4 to 12mm.

Back with a Bang

After a four year absence from our calendars for the obvious reason of the pandemic, the MACH exhibition returned last month…..and wow what an absolute belter!! If you exhibited or visited, you will no doubt concur on what a fantastic event it was – if you didn’t make it, you really missed out…

Nobody needs a reminder of the challenges the industry has faced over the last four years with Brexit and Covid giving every business a turbulent time. Visitors and exhibitors had a valid reason for scepticism over how much of a success MACH would prove to be in the countdown to the biennial event, but as soon as the doors opened on Monday morning, the clouds of the last four years dissipated. As the week progressed, the visitor numbers continued to swell and the smiles of exhibitors grew wider by the minute with order intake growing beyond all expectations for exhibitors.

MTD had its biggest and best show to date and the stand was a hive of activity all week. The digital media crew were streaming live from exhibitors’ stands through the week and the viewing figures went through the roof. The filming covered the latest technology from Hexagon and Star on the first morning with the team moving to the Ceratizit stand after lunch to live stream a prize draw that saw World cycling champion Katie Archibald MBE pick the winner of a British Heart Foundation and Cancer Research UK raffle. The winner, Dave Buchan from Havant-based Monolution won a £6000 Hope HB 130 mountain bike that will be custom fitted for Dave by Hope Technology. Adding to this day-one high note, Ceratizit has since commented that it received a record number of MACH enquiries with over 1500 sales leads to follow-up. Not only will this keep the Ceratizit team busy for some time, but it also emphasises why the manufacturers that aired with caution and decided not to exhibit, really need to be at MACH 2024.

Through the remainder of the week, the digital crew filmed live streams from the stands of Hainbuch, NCMT, Matsuura, Sodi-tech, Hoffmann Group, Intoco, Dugard, Schunk and Chester Machine Tools. With more than 20 MTD staff on-site, the team filmed technology and updates from dozens of exhibitor stands and at the end of each day, exhibitors and visitors were invited to participate in the live daily podcasts. The live MACH updates were also posted on the MTD social media platforms for viewers to enjoy days and weeks after the event closed its doors. 

Commenting on the show, MTDCNC Managing Director Paul Jones said: “MACH 2022 was a huge success for MTDCNC. As always. we looked to offer something new and something different. One of the stand-out points for me was the daily live podcast that we did at 4.30pm every day, we literally had people queuing up to feature. The last one we did on Thursday ran for 100 minutes as we welcomed more than 12 guests that had been exhibiting at the show. It wasn’t just the guests that made it, it was the audience too. In total, our podcasts and live streams saw over 100,000 people engage with our content during the 5 days. We thoroughly enjoyed engaging with visitors and exhibitors alike – roll-on MACH 2024!”

From an MTD magazine perspective, our publishing team with more than 50 years of MACH experience embarked upon a multi-purposed mission to capture as much of the show as possible. Celebrating our fourth anniversary at MACH, the MTD magazine team was treading up and down the aisles looking at the latest technology, seeking out company news, updates, opinion and comment from visitors and exhibitors alike. We also took the opportunity to meet new faces and industry contacts, which for so long had been Teams or Zoom appointments.

Getting back to ‘face to face’ meetings

Thousands of engineers have participated in online meetings and webinars during Covid with sales, technical applications, research and even trials and pre-installation prove-outs being conducted via Teams and Zoom – all without a single handshake taking place. MACH brought our community back together and this was a joyous occasion with exhibitors finally getting the opportunity to connect with new clients; and more importantly, re-connect with long-term customers, suppliers, competitors and most importantly friends. Our publishing team spoke with hundreds of engineers and the one common thread was the joy of rekindling ‘face-to-face’ relationships. 

But let’s not forget, MACH is first and foremost about advancing the manufacturing sector and showcasing the very latest technology. The pre-show message from the Manufacturing Technologies Association (MTA) was all about the ‘post-pandemic’ manufacturing revival, the drive to Net Zero and exploiting the opportunities offered by decarbonisation, the development of innovative technologies shaping advanced manufacturing and additive manufacturing. The show organisers were optimistic that MACH would bring bumper levels of business – not a sentiment confidently shared by many in the pre-show build-up. However, the pandemic has wound-up industry like a coiled spring and the prospect of thousands of innovations making a UK premiere; paraded to an engineering audience that could capitalise on financial incentives such as Super Deduction and AIA available to invest in capital assets – the results were staggering. Everywhere our team looked, there were significant capital equipment sales. For every new machine purchase, there was an ancillary equipment supplier on-hand to support the purchase with tooling, workholding, cutting fluid, software and more. In most instances, machine vendors were directing their new customers to the stands of fellow exhibitors to support the purchase – this micro-climate of collaboration is what MACH is all about. Early reports have indicated that XYZ sold 32 machines at MACH, Mills has reported 22 Doosan sales and dozens of fellow exhibitors from Citizen to GM CNC (Victor) and Mazak to Vollmer and more – the post-show reports of success keep streaming in.

VOLLMER to launch 5S campaign

Sharpening specialist VOLLMER will present its 5S campaign: Sharp, Smart, Sustainable, Social, Strong. On Stand 7C50 in Hall 7, visitors can inspect the sharpening machines, services and digital solutions offered. 

VOLLMER will be showcasing new tool grinding machines from its VGrind range as well as new products for machining carbide-tipped circular saws. Other highlights will include the VLaser 370 laser machine, the VHybrid 260 grinding and eroding machine and the digital V@dison solutions.

With its grinding, eroding and laser machines as well as automation solutions for operator-free machining, VOLLMER is a full-line supplier for sharpening applications. 

With its new 5S campaign, VOLLMER has established five pillars to support its product range- all backed by smart and digital services to ensure maximum sharpness. Thanks to sustainable technologies, VOLLMER plays its part in environmental sustainability. 

GrindingHub will also mark the world premiere of three new VGrind machines, suitable for machining carbide tools. These apply the tried-and-tested technology of the VGrind range: They are also based on the innovative double-spindle concept, which enables multi-level machining with its two vertical spindles. 

VOLLMER has also added two new machines to its range for grinding circular saw blades. They are ideally suited to machining tooth faces and tooth tops as well as the flanks of carbide-tipped saw teeth with a wide range of geometries. These machines feature intuitive operation, enabling users to learn sharpening processes almost instantly. They can also be combined with the VOLLMER automation solutions to operate them around the clock without manual intervention. Furthermore, the subsidiary Loroch GmbH will also show grinding machines for machining, especially HSS circular saws and HW thin-cut circular saws as well as the TC 720 measuring and documentation system.

The solutions will also be on display with the full-line offered by VOLLMER that will include a wide variety of eroding and laser machines. The company will feature the VLaser 370 laser machine, the VOLLMER QXD 250 eroding machine and the new VHybrid 260 machine for eroding and grinding operations in a single machine.

Maintenance, training and finance are at the heart of the services, and these are increasingly digital and web-based thanks to the V@dison solutions. Software solutions control sharpening machines and automated processes and can increase performance. Smart solutions are also available for evaluating process data or cross-connecting users directly with VOLLMER services. Customers can connect to technicians in real-time via the ‘Visual Support’ V@guide solution, or access machine data, information and a spare parts shop online via a personalised customer portal.

GrindingHub 2022 – bringing solutions to the surface

GrindingHub, the new trade show for grinding technology, is set to premiere from the 17th to the 20th of May in Stuttgart with around 360 well-known exhibitors from more than 20 countries signing up for the debut exhibition. The new exhibition intends to become a major international hub for the sector and Dr Wilfried Schäfer, Executive Director of GrindingHub organiser VDW (German Machine Tool Builders’ Association) says: “There is a great sense of anticipation. Most trade shows have been forced to take a break over the last two years, and all participants cannot wait to meet everyone again in person. Digital events simply don’t have the same quality and reach as their face-to-face counterparts.”

With this overview of the new exhibition, MTD magazine gained a deeper understanding of the GrindingHub exhibition from Martin Göbel, the Head of Trade Fairs at the VDW. With GrindingHub set to be the new centrepiece of grinding technology in Europe, Martin explains the concept of the new exhibition.

“Our goal is to make Stuttgart the place where supply meets demand in this prospering international sector. This includes showcasing solutions from the entire value chain – including technologies, processes, machine concepts, automation and digitalization, as well as quality assurance and other related peripheral areas. The aim is to reflect the actual needs and the current interests of customers. Our banner slogan of ‘Brings solutions to the surface’ is meant literally. Exhibitors will be able to present their latest products and projects in two special exhibition areas, the GrindingSolutionPark Industry and the GrindingSolutionPark Science. We intend to perform a balancing act between business and research, while helping to ensure ever closer intermeshing of the two.” 

“Of course, a powerful and competitive trade fair concept also includes effective communication. That is why the experienced international teams of Messe Stuttgart and VDW have launched an effective range of media initiatives in the run-up to GrindingHub. This includes the publication of technical articles and current economic reports – all aimed at providing fascinating insights into the world of grinding technology. Exhibitors and experts are also given a regular say.” 

“An attractive aspect of the GrindingHub is its distinctive supporting program which offers significant added value to customers. This includes the two joint stands, GrindingSolutionPark Science and GrindingSolutionPark Industry that will feature novel, scientifically-based applied production solutions and innovations. This is supported by members of the German Academic Association for Production Technology, WGP. We have also been cooperating with the ‘Schleiftagung’ Grinding Conference, which is organised by the Laboratory for Machine Tools and Production Engineering at RWTH Aachen.” 

“Many of our exhibitors are already established figures in the industry and we are also keen to offer a platform to small and young companies. We are providing an appropriate format for this in the Start-Up Area. The joint stand offers first-class support, appealing to innovative companies on smaller budgets. In addition, we will be focusing on digitalization in production. The latest developments and trends will be on display here. The GrindingHub show will also feature a live demonstration of global data connectivity as used in grinding technology – a demonstration that has already been conducted successfully at EMO Hannover and EMO Milan. It will operate under the umati brand, the joint interoperability initiative of VDW and VDMA. Various specialist forums and seminars will round off the event.” 

“In our eyes, there is no way around offering a digital service – as we have discovered during the pandemic. We are proactively planning the GrindingHub as a hybrid event. We will also be offering a stage to exhibitors during the fair. The digital forum hosts professional streams of 20-minute presentations given at the event. This is a moderated event format. Another aspect we are testing is a video production service for exhibitors. This involves the filming and editing of 60 to 90 second films featuring a tour of the exhibitor’s stand.” 

“We are convinced that GrindingHub is set to become the new hub for grinding technology. Starting in May and then every two years subsequently, Stuttgart will most definitely be the place to be for the industry. It will provide the only opportunity to see the latest innovations and solutions. The reasons are obvious – The trade show has a clear focus and an international orientation. It has a strong thematic position, and the organisers and cooperation partners are confident that the result will be an attractive and professionally run event. Our modern, hybrid trade fair concept is a major factor here.”

The GrindingHub in figures

“Of course, first and foremost we are hoping to impress participants with the quality of the event content. Nevertheless, our registration figures exceeded a total of 362 exhibitors from 23 countries at the end of March with more time remaining. They cover 38 industry sectors related to grinding technology and will occupy around 17,643m² of net exhibition space spread across halls 7, 9 and 10.” 

“The Top 5 industry sectors include cylindrical and non-cylindrical grinding machines, grinding, polishing and honing agents, grinding machines for cutting and machine tools, disposal and treatment of cooling lubricants, and surface grinding machines. There are 205 exhibitors from Germany, followed by 56 companies from Switzerland and 37 manufacturers from Italy. Exhibitors have also signed up from Austria, France, Japan and the USA.” 

“All this shows just how comprehensive and diverse the show is. We cover the entire spectrum of grinding technology and have already succeeded in convincing a large numbers of exhibitors to take part in the premiere of the new trade fair. And that is why we are confident that the GrindingHub show will offer tangible value for visitors.”

VOLLMER connects with visitors

The pace of development at VOLLMER is a sight to behold, and for UK industry engineers that have missed the chance to investigate the latest technology due to Covid – MACH certainly proved the location to re-connect. At the EMO Show last autumn, VOLLMER introduced the new VGrind 360S grinding machine as well as other new technologies. MACH 2022 was the UK exhibition premiere of the new VGrind 360S – and it certainly drew the attention of show visitors. 

The new VGrind 360S grinding machine for the complete machining of carbide rotary tools appeared alongside the VOLLMER CHX/HS and the Loroch Powerstar machines for sharpening circular saw blades, and all machines warranted their position on the stand with several machine sales and a high number of enquiries from UK manufacturers of rotary carbide and PCD cutting tools and circular saw blades. For engineers that didn’t get a chance to visit MACH, VOLLMER has a real treat at the forthcoming GrindingHub show in May – no fewer than five new machine tools will receive their world premiere launches at the inaugural European grinding exhibition. 

Commenting upon the MACH exhibition, VOLLMER UK Managing Director, Mr Peter Allen says: “There was a lot of scepticism in the run-up to MACH after Brexit and Covid having an impact on the industry, but we made the commitment to exhibit and we are delighted that we did. It wasn’t just a great opportunity to demonstrate our latest technology, it was fantastic to interact with both new and existing customers. The return of face-to-face meetings with our customers and the wider industry as well as having the stage to showcase our latest technology was invaluable.”

“It was also a great opportunity to listen to UK industry engineers, not only regarding their journey through the pandemic and Brexit but also to get a greater understanding of the industry’s evolving requirements. Taking the opportunity to listen to manufacturers at MACH is critical to the success of VOLLMER and the ongoing development of our product lines and innovations. Our industry-leading R&D experts are always paying close attention to the requirements of the marketplace; Industry 4.0, connectivity and the increasing costs of energy were subjects raised on numerous occasions at MACH. We already lead the way in these fields, but at the GrindingHub show in May,  our next generation of advanced technologies will really set the   VOLLMER brand apart from its rivals     in these areas.”

Oemeta has heritage performance

With a stunning heritage 3-wheeler car taking centre-stage, courtesy of prestigious customer, Morgan, the team from Oemeta UK enjoyed a thoroughly successful MACH 2022. At the show, visitors approached the stand to learn more about how Oemeta works with Morgan and its Malvern-based machine shop to improve productivity, sustainability, component quality and cost reductions with its cutting fluids. 

With the Morgan car being a great introductory point, show visitors subsequently demonstrated greater interest in the specialist HYCUT and ESTRAMET S 77 products. HYCUT is a mineral-oil-free product and fluid concept that has been tried, tested, and trusted by several engineering giants. The multi-functional capabilities of the fluids mean that all processes can be performed using the same products over and over. The 2-component element allows complete control over machining lubricity and additive levels, independently, allowing total optimisation of the process. Additionally, it can all be recycled back to the machine coolant tanks, substantially reducing waste. ESTRAMET S 77 is one of Oemeta’s latest products and is based on synthetic ester oils. It is a new generation of coolant that combines high performance with cost-efficiency. It is ideal for hard-to-machine materials such as high-alloyed steel, and aluminium and titanium alloys.

Alyson Pettefer, Marketing Manager at Oemeta UK says: “The stand was busy throughout the week and after a long break from exhibitions due to the pandemic, it was great to have face-to-face meetings with industry once again. Our latest mineral oil-free fluid concepts, the HYCUT and ESTRAMET S 77 captured the attention of MACH visitors aiming to improve the sustainability of their manufacturing business whilst improving productivity and machining performance. Having a car on the stand from Morgan, one of our many prestigious customers, was a great talking point and it certainly attracted more visitors to the stand. The enquiry levels were extremely high and our team will have an extremely busy few months following all the leads generated from MACH 2022.”

Transition to Fusion 360 doubles shop floor turnover at Brown & Holmes

As a precision machining subcontract manufacturer and workholding specialist, Brown & Holmes (Tamworth) Ltd supplies high-quality services to blue-chip companies and Tier 1 suppliers throughout the UK, Europe, Asia and the US. With decades of experience delivering machined components to the automotive, aerospace, machine tool, construction, power generation and nuclear industries, the company has recently invested in Autodesk Fusion 360 software to reduce spindle idle times, remove production bottlenecks and improve throughput.

Established in 1939, Brown & Holmes has an enviable reputation for quality, which has seen the Staffordshire company add JOSCAR to its ISO:9001, AS:9100D, ISO:14001, ISO: 45001 and OHSAS:18001 certification list. This philosophy for quality that is matched by its commitment to environmental sustainability has seen the company win significant levels of new business.

Brown & Holmes had been using Autodesk design tools such as Inventor since 2013 for the design of components, fixtures and assemblies, but over the last two years, an upturn in orders saw the company upgrade its licenses to include subscriptions to the Autodesk ‘Product Design and Manufacturing Collection’ (PDMC).

As the name suggests, the PDMC includes a collection of Autodesk products including Inventor and Fusion 360. The increasing demands on the team resulted in Brown & Holmes realising that its existing practices, workflow and CAM system needed a significant overhaul. It is here that Fusion 360 was implemented to help the business grow.

The first instance arrived when Ashley Fielding, a former employee re-joined the company and was tasked with applying manual data input on his CNC machine to produce a lot of plate work for the company’s fixtures. The laborious process was compounded by a CNC controller with limited memory capacity; a process that resulted in extended programming and production times as well as increased risk of data inputting errors. Having used Fusion 360 in a previous role, Ashley suggested utilising Fusion 360 to augment and then replace manual data input.

Unlocking 5-axis with the Fusion 360 Machining Extension

Simultaneously, the Tamworth company had installed a new DMG MORI 5-axis machining centre and the cycles and macros of the existing CAM software proved to be inefficient, and in some cases incapable of manufacturing the parts that Brown & Holmes needed to produce. This made CAM programming a bottleneck that left the new machine sitting idle for extended periods whilst waiting for NC code to be generated. The situation needed to change, and so the Brown & Holmes management team contacted Autodesk and tasked them with creating suitable post-processors for the DMG MORI 5-axis machining centre. Brown & Holmes set up Fusion 360 on a laptop at the side of the DMG MORI machine and this drastically improved spindle uptime. Equally significant is that by training the shop floor machinist to program the parts with Fusion 360, the bottleneck of multiple machines waiting for office-based programmers to create NC code for the shopfloor has been eliminated – the machinists now have the capacity to create their own programs.

Recalling the situation, Paul Bourne, Operations Manager at Brown & Holmes says: “Over 12 months ago we were lucky enough to win a big order, which was on a very tight timescale. The CAD/CAM and offline programming used to be done by our team leaders. With this new order, we are more empowered to undertake the management tasks and filter down the offline programming to the guys on the shop floor. We started with Fusion 360, firstly because it was already included in our Inventor software from Autodesk on the design side of the business. That gave us a natural opportunity to try something new, and it proved to be a very worthwhile success. We now have six seats of Fusion 360 running with the Machining Extension throughout the machines on the shop floor.”

Adding to this, Neil Flint, CNC Operator at Brown & Holmes says: “If I put a job on the table and program it with the Siemens Shopmill CNC control on the machine, it is more than a day of programming for me. With Fusion 360, it’s a lot faster, and probably takes me a quarter of the time, if not less. When parts are more complex and require offline CAM programming, we were reliant on the team leads doing the work. This meant a lot of guys were waiting for the programmers to help them and support them to get the work through the shop floor. Working with Fusion 360, we don’t have to go to an offline programmer anymore – I can do it all myself on the machine with the software that I have.”

Seconding this statement, CNC Operator Steve Sisam adds: “Since using Fusion 360, our spindle uptime has increased massively. We are no longer waiting for programs to be done off-line with several machines in a queue, sometimes we could have machines sitting there waiting for a program. Now, I can do it myself. The spindle is machining quicker, and the parts are coming off the machine faster, and we get left to our own devices. So, a part comes in and I receive a block of material. From there, I will program the part from start to finish with Fusion 360 and take the part through to inspection. I am no longer relying on other people – I can get on and do the job myself and this speeds up the throughput for the business.”

Implementing a change of direction

Of course, the subcontract manufacturer didn’t just purchase six seats of Fusion 360 and everything ‘changed overnight’. In May 2021, with a shopfloor machinist having the facility to program at the machine, the offline programming bottleneck began to ease and spindle uptime significantly improved. At this time, Brown & Holmes won a significant order that would have added to the programming bottleneck. Instead, the company recognised the benefits that one machinist was having with the Fusion 360 and DMG MORI 5-axis machine combination, and subsequently invested in more Fusion 360 seats with the “Machining Extension”. This Fusion 360 cost option unlocks additional strategies and capabilities on top of the base level of Fusion 360, including simultaneous 5-axis machining, toolpath trimming, surface inspection with spindle mounted probes, and automated part alignment. Several operators were trained on Fusion 360 with the Machining Extension, and this has since been rolled out across the shop floor.

With an extremely diverse workload and batch sizes, plus machine tools from a multitude of vendors such as Doosan, Mazak, DMG MORI, Colchester, XYZ, Bridgeport and many others, Brown & Holmes needed an all-encompassing CAM solution that could meet its diverse demands whilst providing reliable post-processers for its extensive machine park. Adding more seats of Fusion 360 gave CAM capabilities to the shop floor, but it was the introduction of the Machining Extension that really stepped things up on the factory floor.

The Machining Extension provides automatic hole recognition and drilling to speed up the drilling of recognised holes in 3D CAD models, something the Brown & Holmes team used to replace manual data input for the programming and machining of plate work. With regards to milling operations, the Extension provides intelligent strategies, like Steep & Shallow to automate the programming of complex parts as well as a complete range of innovative multi-axis toolpaths to safely streamline 4 and 5-axis machining. To provide complete programmer and operator confidence when streamlining both programming and machining cycles, the Machining Extension also provides comprehensive multi-axis collision avoidance that incorporates the tooling, workholding, fixturing and tool holding.

CNC Operator, Ashley Fielding adds: “With some of the higher end cutters that we use, the speeds and feeds have to be to a very specific range. So, the tooling library in Fusion 360 has given us the ability to standardise across the shop floor and it gives us a back library of the tools that we have used on particular jobs and materials. This means we can tell the guys on the shop floor what tools work and what tools to use on particular jobs and material types, so they will have no problems at all. This also enables us to even increase the speeds and feeds across the shop floor, which is significantly improving our throughput by reducing our cycle times.”

Concluding on the installation of Fusion 360, Paul Bourne says: “Since having Autodesk Fusion 360 on-site, we have doubled our turnover! Our NCR (non-conformance reporting) has been reduced by 34% and the costs incurred by those NCR’s have also been reduced by a similar level. Additionally, it is creating more pride in the work that we are doing and that upskilling of the guys on the shop floor has given them more impetus and more motivation to further themselves and their contribution to the business. In hindsight, I wish we had bought Autodesk Fusion 360 sooner.”

Metal Additive Manufacturing taking care of our health

In the majority of manufacturing scenarios, time (cycle time) is one of the most important parameters that directly affects a company’s element of competitiveness and profitability. However, the factor of ‘time’ is seldom a matter of life and death. Manufacturing a component can be optimised to reduce costs, but if the cycle time is too long, it probably wouldn’t end up causing amputation or death. This is not the case in the medical sector. Accidents could happen at any time and a prompt medical response is essential to save a life, an organ, or a limb. In this article, we discuss how rapid prototyping and production could help with saving lives. By Kasra Mehraky.

Ever since its introduction into mainstream manufacturing, additive manufacturing has been in demand in the biomedical industry. Nowadays, the applications of this method are no longer limited to medical research and development, the area in which it was initially used due to its rapid prototyping feature, and it has become a popular manufacturing method in several areas in the biomedical industry. Owing to the countless advantages of AM manufacturing such as flexibility, availability and cost-effectiveness, it now has a wide range of medical applications including the production of dental fixtures and jigs, hearing aids, prostheses, implants and even surgical instruments.

Advances in additive manufacturing make the production of all these components quicker, less expensive and above all customisable, making them available for a larger number of patients in need. This is especially the case in remote places and third-world nations without access to conventional expensive manufacturing equipment. The unmatched flexibility of this method allows for affordable production of customised components, making implants and prostheses matching with each individual’s anatomy and situation. This brings more comfort to the recipient. Similarly, 3D printing technology is a practical learning and diagnosis supplement for both students and surgeons, since it can be used to provide realistic models of any patient’s organs. This way it’s possible for doctors to do a more extensive analysis of the patient’s condition before surgery, aiming to reduce the risk and duration of the operation. 

The emergence of additive manufacturing in the biomedical industry has especially contributed to manufacturing metal implants and orthopaedics science. Using this technology, numerous parts of the skeleton can be replaced, ranging from knee joints and ankle bones to acetabular cups and parts of the skull. 

Among the metals frequently used for manufacturing implants, titanium and cobalt chrome alloys are the most common. The mechanical properties of titanium such as strength, low density, corrosion resistance and non-reactivity have earned it the title of the most biocompatible metal. For this reason, cranial plates, dental implants and small joint implants are often made out of titanium. Cobalt chrome alloys are similar to titanium in terms of biocompatibility but offer additional strength and hardness, making them the main material for heavy joint replacements in the knees, hips and shoulders. In addition to the great number of advantages of using additive manufacturing for implant manufacturing, using this method with titanium has the added benefit of making the reduction of elastic modulus of porous titanium possible. This way the elasticity mismatch between the implant and the human bone can be almost eliminated, reducing stress shielding and ultimate reduction of bone density. 

The foremost advantage of metal additive manufacturing over other manufacturing methods for biomedical applications is the production of affordable bespoke components. Customised implants produced according to each person’s size and anatomy help to achieve maximum contact and stability, resulting in a shorter recovery period, improved healing, adaptability and chance of success. Among the many real-life examples of this are ribcage implant surgery, successfully performed in several countries, and the replacement surgery of a talus bone of a patient with a 3D printed titanium implant, without which the patient’s ability to move the foot would be lost.

Another improvement in metal implant manufacturing made possible by metal 3D printing is the facilitated production of geometrically complex and lightweight implants. Typologically optimised implants can be manufactured using data from standard medical imaging, which would alternatively require meticulous design and calculations using machining or other conventional methods. Even so, some shapes are impossible to produce or require time-consuming and complicated tooling to manufacture with machining. Needless to say, this feature of AM contributes to the duration of healing and the chance of success. 

Moreover, using bespoke implants can in many cases eliminate the necessity for follow-up removal and/or correction surgery due to implant migration, breakage or rejection. One exemplary case is the surgery to correct degenerative cervical spine condition, in the process of which the trabecular bone is replaced. A meticulously manufactured titanium implant fuses with the surrounding structures more easily, making subsequent bone graft surgeries non-essential. 

Furthermore, the flexibility, ease and cost-efficiency of metal implant manufacturing made possible by AM technology accelerates product development and results in a shorter time to market. This can in many cases save a life. 

With all this in mind, it is important to clarify that additive manufacturing is rarely the final stage of metal implant manufacturing. Since cell behaviour is strongly affected by surface properties, achieving ideal surface roughness induces better cell response and reduces the chance of rejection. Therefore, machining is often used as a post-production process for finishing and support removal. This way, each technology is used where it brings the greatest benefit. Interestingly, hybrid machines are one of the most recent advances in manufacturing that combine 3D printing and machining for this type of purpose. Such machines can further reduce production time, cost and time to market. 

In conclusion, additive manufacturing technology has become an efficient option for manufacturing implants, medical devices and organ models. Due to its many benefits including affordability, flexibility and availability, it is now widely used for production in many biomedical areas, especially for metal implants. Additive manufacturing is most effective when combined with precision machining, as the former makes quick and cost-effective production of customisable implants from medical imaging data possible, and the latter ensures a successful surgery by achieving the desired surface quality and roughness.

New lines grab visitor attention

The return of the MACH exhibition provided a welcome boost to the industry, and Industrial Tooling Corporation (ITC) revelled in the opportunity to demonstrate all its latest innovations.

MACH was the first opportunity for manufacturers to investigate all the new product lines and have face-to-face discussions with experts in a large scale exhibition environment. For ITC, its cutting tool experts certainly noticed a renewed vigour from engineers visiting the show and their appetite to learn more and invest in the very latest cutting tool technologies. Commenting upon the event, ITC Director Georgia Graves said: “Opportunities to have face-to-face meetings with the industry have been limited by Covid for too long. The timing of MACH has been perfect and our team of cutting tool experts has certainly witnessed their busiest MACH exhibition to date. The combination of limited contact with customers, potential customers and technology partners, and the build-up of countless new product lines that had yet to be seen by much of the industry were factors that created a huge wave of interest in all of the new technologies developed by ITC as well as our partners WIDIA, BIG KAISER, Kemmler and Bass. We are delighted with the lead generation and enquiry level from the show.”

One of the new ITC products that gathered interest was the 6054 Series of end mill developed specifically for the machining of steel and exotic material types. The geometry of the 6054 Series has a centre cutting geometry with harmonic fluting to maximise material removal rates and swarf evacuation whilst minimising vibration to enhance surface finishes and tool life. This chip evacuation is further enhanced by extremely efficient chip breakers. The 6-flute series 6054 Series is available with diameter options of 6, 8, 10, 12, 16 and 20mm with a length of cut from 18mm on the 6mm diameter tool through to 60mm on the 20mm diameter end mills. 

With a team of WIDIA experts at MACH, the indexable insert line from this globally renowned brand was also extremely popular at the show. Of particular interest was the new WIDIA™ M1600 face mill series that received its MACH debut. Also proving to be a crowd-pleaser alongside the M1600 was the impressive M8065HD milling system for machining steel and cast-iron materials. Designed with eight cutting edges and extra-wide chip gashes, the new M8065HD can achieve unfathomable depths of cut while producing high metal removal rates during face and shoulder milling applications. 

From the BIG KAISER stable, ITC introduced the expanded line-up of Smart Damper-equipped, arbour-style face mill holders that support face mills with diameters of 80mm or 100mm with an arbour pilot diameter of 27mm. The Model SDF57 assembly has an outside diameter of 71.8mm and allows users of 75mm face mills to access up to 500mm of reach, the longest tool assembly in the industry using standard components. Also from BIG KAISER was the Mega Synchro Tapping Chuck. 

For engineers that didn’t get the opportunity to attend MACH 2022, ITC would be delighted to update manufacturers on all the latest innovations that set the halls of the NEC alight with enthusiasm in April.

Smart exhaust company takes brakes off

A manufacturer of high-quality motorcycle exhausts is unlocking its capacity to innovate and grow with the support of Made Smarter. Fuel Exhausts, based in Kendal, is investing in a 3D scanner to capture digital versions of parts and components, 3D CAD software, and a 3D printer for producing prototypes of end caps and parts for exhausts.

The £30,000 integrated digital design solution, which has been match funded by the Made Smarter Adoption Programme in the North West, will enable the business to design and test product ideas in virtual reality before manufacturing them. It will radically change the way the business operates, making the prototyping process 14 times quicker, increasing productivity, eliminating waste, reducing costs and increasing profitability.

Meanwhile, 3D scanning technology will introduce reverse engineering of parts into the business, opening new markets. The investment will also create two new production operative jobs.

Damian Turner, who runs the business with wife Louise, said: “We are a small but very dedicated team who strive to provide a fantastic product with second to none customer service. Over the two decades we have been trading, digital technology has moved to the forefront in many areas of manufacturing, with the support of Made Smarter we are ready to embrace the opportunity it offers to manufacture prototype parts and new products in-house and move into other areas of production for parts and accessories to complement our current range of exhausts.”

The 3D scanning technology will allow Fuel Exhausts to scan a motorbike to give it the capability of reverse engineering parts. It will also enable the business to test new products and design in a virtual environment, before using 3D printing technology to produce prototypes quickly and cost effectively.

Donna Edwards, Made Smarter’s North West Adoption Programme Director, said: “We are delighted to be supporting Fuel Exhausts on its digital transformation. It is a superb example of a business using technology to transform how it designs, tests and manufacturers products.

A cut above

MACH proved a resounding success for AAG WARDJet as its compact A-Series waterjet cutting system demonstrated how a small footprint machine can cut through virtually any material imaginable. 

With a footprint of just 1.75m by 2.31m that facilitates a cutting area of 1.25 by 1.25m, the A-1212 machine on the stand demonstrated its flexibility, capability and precision. With a helical rack and pinion system and a robust build quality, the A-1212 achieves a linear positional accuracy of +/-0.08mm per metre with repeatability of +/-0.05mm. This level of precision and repeatability within a small footprint combined with the potential to cut virtually any material generally captured the imagination of show visitors. 

Commenting upon the show, Managing Director for  EMEA & Asia, Mr Chris Arend said: “MACH 2022 was a great success for the Manufacturing Industry as a whole, having been 4 years since the last edition you could sense the anticipation, and we were not let down, the exhibition hosted some great stands and lots of innovation and we were rewarded by not just the number of visitors but the quality of visitor, I believe the focus of visitor has changed to being one of need not interest, in other words they have a specific requirement to attend the show.”

“It was our first time at MACH and we were received very well, our showpiece the A-series certainly attracted great interest, a machine offering a very compact footprint but with a powerful offering able to meet many different market sectors. The exhibition also offers the ability for us as suppliers to network with the other exhibitors, discuss the many difficulties facing the industry but also share the great success stories.”

Super effective for Superalloys

Superalloys – metal alloys, which reflect their complex alloyed structure, have become one of the main engineering materials. They feature extremely high elevated temperature strength, and therefore often are referred to as high-temperature superalloys (HTSA) or heat-resistant superalloys (HRSA). The history of superalloys started with the development of gas-turbine engines that required reliable materials for high operating temperature ranges. As a result of intensive research and progress in metallurgy, modern superalloys (SA) provide a long service life for working temperatures of more than 1000°C.  

Superalloys are very common in the medical industry, which effectively uses them for prosthetic implants in orthopaedic surgery. In addition, superalloys have become widespread in power generation and the oil and gas industries as crucial materials for essential parts of various devices.

Exceptional high-temperature strength and corrosion resistance are the undeniable advantages of superalloys. However, there are two sides to the coin. Superalloys are not only highly-priced, but their machinability is poor. This can pose manufacturing challenges. The specific cutting force that characterises the resistance of the material and defines the mechanical load on a cutting tool is high for superalloys. Although the main difficulty is heat, superalloys have poor thermal conductivity. Elemental and loose chips, which are generated when machining superalloys, do not provide adequate heat dissipation from the cutting zone. A tendency to work harden also makes the situation worse.

A manufacturer can deal with various SA workpieces such as cast, wrought and sintered. The workpiece fabrication methods also have an impact on machinability. For example, the abrasiveness of forged workpieces is higher than cast and is substantially lower in comparison with sintered workpieces.

Consequently, a cutting tool is under significant thermal and mechanical load, which dramatically reduces tool life. Therefore, when machining superalloys, the cutting speed is directly connected with the heat generation during chip removal and it is considerably lower when compared to other common engineering materials such as steel or cast iron. The direct result of the cutting speed limitation is poor productivity. Hence, overcoming machining difficulties and increasing productivity are the main challenges for the manufacturer of SA parts.

According to the ISO: 513 standard, superalloys together with titanium alloys relate to the ISO-S group application. Depending on the prevailing element, superalloys are divided into three types: iron (Fe), nickel (Ni) and cobalt (Co) based alloys. Machinability drops in the specified order; from the iron-based alloys, which can be compared with austenitic stainless steel, to cobalt-based alloys that represent the most hard-to-cut materials in the group.Increasing efficiency of machining superalloys has become the focus of various scientific research and technological improvements. The result has been a significant advance in producing SA components. Manufacturing has effectively embraced new machining strategies and innovative methods of coolant supply, such as high-pressure cooling (HPC), minimum quantity lubrication (MQL) and even cryogenic cooling has successfully been introduced. This has taken the productivity of machining superalloys to a new level. However, like in the case of titanium alloys, the key element for improving the productivity of SA machining is a cutting tool that directly removes material layers from a workpiece that produces chips. A cutting tool features the tool material and its geometry, which determines the tool’s triumph or failure.

Today, coated cemented carbides are the most common materials for cutting tools for machining superalloys. The development of a carbide grade, in which strength and wear resistance will be mutually complemented is a tricky process that requires an appropriate carbide substrate, coating composition and coating method. To the amazement of those who believe that the breakthrough possibilities in this direction are almost exhausted, cutting tool producers continue to create new effective carbide grades. Additionally, in machining superalloys, ceramics are another tool material that enables substantially increased cutting speeds.

If tool materials are connected mostly with material sciences and metallurgy, cutting geometry is more in the tool design field. Ensuring high-performance geometry requires deep engineering knowledge and technology skills. On the one hand, to minimise heat generation and work hardening, a positive rake angle, a large enough clearance angle, and a sharp cutting edge are needed. On the other hand, such a shape weakens the cutting edge that should withstand a considerable mechanical load. Therefore, the correct cutting-edge design becomes a critical success factor. Sintered carbide inserts have the advantage of enabling complex chip forming and chip breaking shapes for insert rake faces. Today, computer modelling of chip formation and pressing processes using finite element methods provide an effective tool to optimise the shapes that are already in the design stage. In solid endmills, a variable pitch design results in improved vibration strength. Cutting edges of these endmills are produced by grinding operations and to eliminate flaking and edge defects, strict adherence to technological process requirements are highly important.   

Cutting tool manufacturers pay a lot of attention to improving their product portfolios for machining superalloys. ISCAR’s new carbide grade IC806 can be an excellent example. It was introduced for face grooving superalloys and austenitic stainless steel. It was then successfully adopted by ISCAR’s threading and deep drilling lines. This grade has a hard submicron substrate and PVD TiAlN/AlTiN coating with post-coating treatment according to ISCAR’s SUMO TEC technology. IC806 provides notable resistance to flaking and chipping and maintains reliable and repeatable results. 

When machining with carbide endmills and exchangeable heads, grade IC902, which combines ultra-fine grain substrate and nano-layer PVD TiAlN coating, ensures extremely high wear resistance and prolongs tool life. This demonstrates good results in producing devices for replacement knee and hip joints from cobalt-chrome alloys (Fig. 1). 

ISCAR has significantly extended the range of products for ISO-S applications made from various cutting ceramics such as silicon nitride, SiAlON, and whisker-reinforced grades. The newly introduced ceramic items have replenished both indexable inserts and solid endmills (Fig. 2).

The latest rake face designs F3M and F3P ISO turning inserts are intended specifically for hard-to-machine austenitic stainless steel and superalloys (Fig. 3). Their positive rake-angle geometry reduces the cutting force while the set of deflectors on the rake face improves chip control. In ceramic double-sided inserts, ISCAR has added new chamfered and combined (chamfered and rounded) cutting-edge options.

ISCAR has enriched the range of solutions intended for high-pressure cooling with new indexable cutter bodies and tool holders. For example, thermal shrink chucks with polygonal taper shanks, which have coolant jet channels along the central bore, have been replenished by the tool holder product line. In conclusion, the need for increased productivity in machining HTSA is a continuous challenge for cutting tool manufacturers, and new effective tool developments are likely to come shortly.

Okuma to reveal its ‘best-kept secret’

Okuma will reveal its best-kept CNC grinding machine secret at GrindingHub 2022. The company will present the GI-20NII and the GP25W at its 91m² stand located at Booth A18, Hall 10 of the Messe Stuttgart exhibition centre. 

Available in the UK from NCMT, Okuma has a reputation for innovative turning and milling machines featuring proprietary CNC control systems, but it has also been very active in promoting the development and production of innovative grinding machines for over 100 years. At GrindingHub 2022, Okuma will show two innovative products that deliver precise grinding with maximum dimensional accuracy.

The GI-20NII internal grinding machine for profile grinding and automated series production is precise, highly efficient and reliable thanks to the five-sided hydrostatic axis guide that has proven successful at Okuma. The company’s Thermo-Friendly Concept achieves thermal stability and better machine performance. With the aid of the numerically controlled axis, the machine can reach a higher removal rate at faster cycle times, whether in the two-spindle version or the four-spindle version.  

The machine can be equipped with a top speed range of 15,000rpm to 150,000rpm, depending on requirements.

 The GP25W is ideal for the high-performance machining and high-precision mass production of small parts to be used in either the automotive industry, household appliances or hydraulic systems. Users benefit from short machining times thanks to fast axis feed rates. What’s more, the grinding disc speed is adjusted automatically and unwanted resonant frequencies caused by the machining process are monitored to keep component accuracy consistently high. Both of these grinding machines are supplied with Okuma’s OSP-P300GA CNC control system.

Batten & Allen announce Bruderer investment

A specialist in stamping, plating and the assembly of high precision parts is celebrating its 50th birthday in style after announcing a new £400,000 investment. Batten & Allen, which employs 120 people in Cirencester, signed a deal at MACH to purchase a new Bruderer high-speed press that can produce six million components a day.

The company will use the 28-tonne BSTA 280-75B2 to stamp precision parts for use in electrical applications across automotive, aerospace and consumer goods. Fitted with a high precision mechanical feeder, the machine offers a 750mm bed to accommodate complex press tools and comes with the latest control technology to provide benefits, such as Automatic Ram Shut height adjustment at micro-adjustments while the press is under acceleration and decelerated loads.

“Bruderer presses are known throughout the industry for their precise control and repeatable accuracy, two of the reasons why this machine will be our 30th from them,” explained Ian Mackinnon, Batten & Allen CEO. “The components we make are extremely precise, often to a few microns. This means we require a machine that could deliver that level of precision, time and time again – in fact, volumes can run into millions of parts every day.”

Batten & Allen exports 85% of its turnover to customers across the automotive, aerospace, electronics and consumer goods sectors and, following a major surge in orders, is expecting sales to hit a record-breaking £20m at the end of this year.

Adrian Haller, Managing Director of Bruderer UK, was delighted that the strategic partnership has been extended even further. “Batten & Allen’s production facility is built on the power of our presses, dating back nearly 50 years, and involving the installation of more than 30 machines, ranging from 20 tonnes to 50 tonnes.

“The latest BSTA 280-75B2 can operate up to 1500 strokes per minute and the large press tool bed means it is extremely flexible and supports quick changeovers. The press will run continuously across three shifts and 24-hours per day – now that is what I call reliable performance.”

Improving quality control in medical knee joint production

G&G Präzisionstechnik GmbH, located near Göppingen, is a young and dynamic company offering high-quality industrial manufacturing of precision parts made of different materials. The business takes on projects of various sizes, from individual parts to small series runs that range across industry sectors as diverse as aerospace, medical technology and racing. 

The business’ uncompromising selection of the highest quality production materials, using the most modern machine tools, guarantees production quality at the highest level across a huge selection of small-to-medium-sized parts. Powerful and precise machines are the basic prerequisite for reliable and high-quality products at G&G. 

Michael Nonnengässer, master orthopaedic technician and Managing Director of Nonnengässer Orthopedie Technik in Donzdorf, contacted Martin Gabriel, founder G&G Präzisionstechnik, with a very special request in the field of orthopaedics. The company is a leading provider in the field of orthopaedic technology in the region and in their daily work, they treat many patients with varus and valgus gonarthrosis, commonly understood as knee malalignment.

“We were dissatisfied with the results of the long-term correction of the orthoses that are on the market and we started looking for a partner who could develop our joints that would help to meet our expectations,” recalls Nonnengässer. 

The idea of having easily adjustable joints is very appealing, but the implementation is challenging, as those joints should be relatively narrow, small and light. But G&G took on the challenge and developed the first prototypes.

“I found the topic exciting overall,” explains Gabriel. “Above all, it gives us a new challenge that is not always there every day, and I find it very interesting to develop new things, especially innovative new things, and that was ultimately the theme.”  

Prefabricated, individually manufactured orthoses do not always work well. The point was not to invent something completely new, but simply to optimise things that are already there. “You don’t have to reinvent the wheel, but if we simply discover a problem, we have to get to work on it to perhaps improve things and, let’s just say, improve mobility for our customers,” explains Nonnengässer. 

Nonnengässer’s target group are patients with osteoarthritic knee joints, more commonly known as typical bow legs or knock-knees. “This is a problem that causes problems like pain and restricted mobility in old age, and operating is often the only solution. These joints or orthoses aim to bring a gentle correction to it and to achieve pain relief for the patient.”  

“G&G has been working with Hexagon for many years and we are very satisfied,” says Gabriel. “As a high-quality standard that is always our guideline, we ensure the quality standard of our products according to DIN EN ISO: 9001 certified processes thanks to our extensive measuring and testing systems. One important principle in this is error prevention and attaining zero-defects is our target. To guarantee the constantly growing quality requirements, we rely on the most modern technology in the area of measuring, which is why we use an Absolute Arm from Hexagon with a measuring range of 2m and a measuring accuracy of less than 5 microns. The system offers us portability and therefore allows for workpieces to be checked directly on the machine.” 

For the new joints project, G&G use the Absolute Arm with Hexagon’s flagship modular 3D laser scanner, the Absolute Scanner AS1. This is applied to digitise the components, the actual part and the nominal part. From this, they could calculate a retrofit and then do the best fit alignment to quickly check everything fits before beginning the machining process.

The new joints that G&G can produce with this process provide a much gentler correction, like braces. “With those upgraded orthoses, the knee joint is now simply gently pressed into its position, as it should be. The pressure points have been completely changed by this longitudinal shift,” explains Nonnengässer. “The result is a better correction and, much more importantly, a better acceptance from patients, especially because we can readjust the orthosis at any time analogous to the course of therapy. We do not fix the leg in a way that is unchangeable.”

“We have a lot of measuring technology in our quality assurance department from Hexagon. But the portability of our Absolute Arm makes all the work easier for us. There is no longer any need to take the part to be measured away from the production machine, bring it to the quality room and do the check there. The arm’s mobility allows for usage everywhere, including directly on the machine where the part is being manufactured. That’s an incredible productivity enhancement.”  

ETG Ireland takes subby from manual to CNC machining

Founded in 1992, P&T Precision Engineering has an established reputation as a subcontract manufacturer that specialises in the production of jigs, fixtures and machined components for the food, medical and pharmaceutical sector. Historically a manual machine shop, the County Kildare company has made the transition from manual to CNC machining with the support of the Engineering Technology Group (ETG) Ireland. 

Discussing the transition from being a manual machine shop to a CNC facility, Mr Darragh Walsh from P&T Precision Engineering says: “We were a small family company with six employees and we decided to invest in CNC equipment from ETG. We ended up buying quite a lot of new equipment. This has helped us to grow in the industry sectors that we need to grow in, and it has helped our customers to get more products with shorter lead times. In a short space of time, we have gone from six staff to 22, but we have also grown our number of machines – and we hope to grow that into the future as well.”

Jamie Fletchmore from ETG Ireland says: “P&T was an up and coming family run business that was coming from manual machines into the CNC world. They approached us and said they wanted to make that advance from manual to CNC machining. We sat down and spoke about the first machining centre and we introduced them to the Qauser MV184. From there, we migrated on every two years and they were buying more technology, which included the Nakamura AS200L turning centre and then two years later they purchased another Qauser MV184.”

The first step the Naas based company took was to invest in the Qauser MV184 vertical machining centre. The Qauser MV184 provides a spacious work envelope with X, Y and Z axes of 1020 by 610 by 610mm that travels over a 1200 by 600mm bed with a load capacity of 500kg. The BT40 taper spindle machine provides a maximum spindle speed of 12,000rpm that is supported by a 30 position ATC. 

“This type of machine is a big step up from where they were, machining parts on manual machines in multiple operations. With the Qauser MV184, P&T were able to take those manually machined parts from drawing and CAD model straight into the machine with a finished part coming off. So, they were able to get the parts through the shop floor much faster and that also reduces the downtime involved with going from one operation to another with the manual process. Investing in our machines and technology has enabled P&T to move through different types of components and different kinds of materials, especially harder materials. This has allowed P&T to get into markets that they were not used to working in,” continues Jamie.

“It has opened doors and opportunities that has led the company to then look at the Nakamura AS200L turning centre. This machine opened P&T up to a new range of products that they were able to look at. They were making parts in multiple operations from a lathe point of view and now, by using the Nakamura AS200L turning centre they can finish those parts complete in one operation. P&T are now able to do all of the milling, drilling, tapping and then also transfer parts to the second spindle, so the part is coming off the machine in one complete operation as opposed to multiple operations.”

“P&T are a very creative company and they do a lot of design work for the companies that they work with. So, they came to us with particular types of work and asked if they could do it on our machines. We sat down with them and supported and guided them through the different ways that we could approach jobs – in a way that was different to what they were doing in the past. That has enabled P&T to create much better parts, much quicker whilst retaining and improving upon the precision and the tolerances of the parts that they are making,” continues Jamie.

Darragh Walsh continues: “We went to ETG because they give great support and service and they also provide fantastic quality machines with great repeatability and durability. We have never had any issues with any machine that ETG hasn’t been able to fix within a couple of hours. The Nakamura AS200L turning centre has enabled us to machine components in a much faster time because there are fewer setups. So, instead of taking jobs from the lathe to the mill – we can now do it all in one shot. This has decreased our machining times, it’s reduced our delivery times and it also means we can get more parts through the machine shop.”

Exigo-UK invests in Nukon fibre laser

Rochdale-based Exigo-UK is all set for high-performance in-house laser cutting, after purchasing the Nukon 2D fibre laser machine that was displayed on the Ingenium Integration stand at MACH 2022. 

Makers of the Exigo range of commercial gym equipment were becoming increasingly tired of relying upon external suppliers for the laser cutting of mild steel components for use in the manufacture of several of its products. Having decided to invest in fibre laser flat sheet metal cutting equipment, the company was faced with finding a machine that would fit into a limited workspace, offer high levels of performance, be economical and accessibly priced. 

“We decided that a trip to MACH 2022 would make good sense, as it would allow us to compare a number of fibre laser machines at the same time,” comments Exigo-UK Managing Director, Darren Golden. “Although it wasn’t our intention to buy during the visit, it became clear that choosing the Nukon 2D machine from Ingenium Integration would be a good business decision. It offered high levels of performance, an exceptionally compact footprint and was affordable. The Ingenium Integration team was exceptionally helpful in demonstrating how the Nukon machine would meet our needs. It was also pleasing to see that with 4kW power, the laser would be frugal to run and only require access to mains electricity. We anticipate the machine paying for itself over the next 12 months.” 

The Nukon 2D fibre laser machine purchased by Exigo-UK during MACH 2022, and soon to be installed at their Rochdale manufacturing centre, is one of Nukon’s Eco 315 4kW models. Specially developed for first-time laser users, organisations wishing to add value to in-house manufactured products, and subcontractors either starting out in 2D laser cutting or with demanding flat-bed laser metal cutting requirements. 

The machine bought by Exigo-UK is also equipped with optional adaptive beam optimisation and optional cut-line beam-shaping technology – a capability that provides improved cut-edge finish and easy, rapid cutting of different sheet thicknesses and metals. Nukon Eco models have a compact 7m by 7m footprint and can accept sheet metal of up to 3m by 1.5m. The machines are available in power options from 1kW up to 4kW. 

“It was a pleasure to meet the team from Exigo-UK at MACH 2022, get to fully understand their cutting requirements and assist in their decision to purchase the Nukon Eco 315 4kW fibre laser,” comments Steve Haddrell, Sales Manager at Ingenium Integration, the official UK and Ireland distributors of Nukon’s laser machines.

Good form

After a long break, the Formation Media team was thrilled to be back at MACH. The team enjoyed reconnecting with familiar faces and meeting many new people and businesses. In addition, Formation was fascinated to learn about the latest developments across the industry and loved seeing lots of innovative new products from those exhibiting.

ISO: 9001 certified, Formation is a digital marketing agency for the manufacturing sector. Company Director Dave Dunlop says: “You’ve shopped around and bought yourself some fancy new machines. But do you know how well your website performs to get those products promoted and sold? Is your site easy to navigate and optimised with your industry keywords? Are your socials selling your services or looking a bit sorry for themselves? Do you think your website could be ranking higher? We are here to feed your machine!”

Floyd demos light-up show

With two sliding head machines on its stand at MACH 2022, visitors to the Floyd Automatic Tooling stand enjoyed the diversity of the Floyd product range. The Star SR-32J and Citizen L12 machines were fully tooled-up whilst machines on both the Star and Citizen stands were demonstrating the extensive portfolio available from Floyd Automatic. 

The two machines drew a record enquiry level and an unprecedented level of interest in both the ‘live demos’ and the static displays of established and new product lines. Floyd gave MACH debuts to the Swiss cutting tool brand Denitool and the German JBO brand – both drawing significant interest at the show. 

Commenting, Floyd Automatic’s Managing Director, Mr Richard Floyd said: “MACH was once again a huge success for us. After a four year absence of the MACH exhibition from our calendars, this show was all about re-connecting with customers new and old and demonstrating many of the innovations we have to offer. The show visitors were certainly upbeat, enthusiastic and keen to investigate new technologies. We would also like to thank both Star and Citizen for loaning us machines for the exhibition. The synergy we have with these leading brands was evident as stand visitors were intent on learning more about the technology we offer and how it works with the industry’s leading sliding head turning centres.”

“From a product perspective, incorporating the Denitool and JBO brands into our offering drew significant interest at MACH. Likewise, the SRS range of collet clamping heads from Schaublin and the Quick-Change Tool Systems from Swiss Tools were very well received, and having technical support from Schaublin at MACH undoubtedly enabled us to promote the merits of this technology, especially on turret type machines. Other notable products of major interest were theJBO brand – both drawing significant interest at the show. Commenting, Floyd Automatic’s Managing Director, Mr Richard Floyd said: “MACH was once again a huge success for us. After a four year absence of the MACH exhibition from our calendars, this show was all about re-connecting with customers new and old and demonstrating many of the innovations we have to offer. The show visitors were certainly upbeat, enthusiastic and keen to investigate new technologies. We would also like to thank both Star and Citizen for loaning us machines for the exhibition. The synergy we have with these leading brands was evident as stand visitors were intent new SWITCH-Line Series of interchangeable turning tools from Applitec and the Microconic over-grip collets from MASA tools. We also had Mikron Tool on the stand next to us, so experts from their team were also available to support us with technical enquiries. The support of our technical partners and the ability to demonstrate the innovations on Star and Citizen machines were major contributors to our success at MACH. Our reputation as the ‘go-to’ company in the sliding head tooling segment was also more prominent than ever before with more companies coming to our stand following recommendations from fellow exhibitors.”

Curtain comes down on successful show for Kerf

The return to the MACH exhibition proved to be a resounding success for Kerf Developments. The technological leap and the steps forward that Kerf has taken since the last MACH show were evident for visitors, customers and even competitors to see at the showpiece manufacturing event. 

Commenting upon the success of the show, Sales Director Craig Walsh says: “Visitor numbers were consistently high throughout the week and of a good standard. There were certainly manufacturers looking to invest in the latest productivity tools and this resulted in two machine sales at the show with many more manufacturers planning to place orders in the coming weeks.”

At MACH, the market-leading RUR2500P high definition plasma cutting machine created a spark of attraction for show visitors with its UltraSharp cutting technology that has been enhanced with new advanced technologies. Additionally, Kerf introduced the new Fineline 300 Plasma unit from Lincoln Electric that incorporates Advanced Piercing Technology and a new Watermist system – the technology built into this new unit genuinely blew customers away and the enquiry levels by the end of the MACH week were unprecedented.

As Craig adds: “Laser users showed considerable interest in the latest stainless steel and aluminium water mist process. They were also very impressed with the cut quality that UltraSharp could achieve on mild steel and demonstrating this created a huge level of enquiries. This was particularly so on thicker applications from 10mm through to 50mm where some laser processes appear to start to lose edge quality.”

The show debut for the new Optima waterjet cutting machine allowed Kerf to use MACH to really set its stall out in the waterjet segment – and show visitors proved suitably impressed. “Waterjet cutting live at MACH generated a lot of interest. Visitors were impressed by the wide range of materials that the process can cut and the excellent cut quality that we can achieve with the Optima machine,” continues Craig.

Fabulous MACH for Filtermist

Filtermist reported a 60% increase in enquiries at this year’s MACH show compared with the 2018 exhibition. The UK provider of LEV extraction systems showcased some of its latest clean air innovations following a four-year hiatus caused by the pandemic. 

The company’s oil mist filters received a significant level of enquiries, as did filters from sister company Absolent AB and Kerstar’s industrial vacuum cleaners which are manufactured at its Shropshire base. Lydia Barber, Director of Group Marketing, commented: “We wanted to display the wide range of solutions that we offer, including some of the products that we manufacture here in the UK and our comprehensive aftermarket services. Visitors are always interested in Filtermist oil mist filters as they are so well known – in addition to our stand, our units were also on seven OEM stands around the show which was fabulous to see.”

The exhibition was the first time Filtermist had shown the Kerstar brand of industrial vacuum cleaners to UK manufacturers and the products were the subject of a huge amount of interest. Visitors were particularly interested in the swarf and coolant vacuums as they are perfect for cleaning up excess swarf and coolant in and around CNC machines. There was a clear focus on the ATEX and Type H rated units from companies that need to comply with DSEAR regulations and those that work with potentially hazardous dust, including dust found in additive manufacturing processes.

Lydia concluded: “The energy levels and enthusiasm from both fellow exhibitors and show visitors were inspiring and we are very confident that the trajectory of the UK’s manufacturing industry will continue to increase following a challenging few years. We are proud to be part of, and to be able to support, this forward-thinking industry.”

Quickgrind dances a limerick with knee joints

By Mike Stobart

As a leading UK manufacturer of solid carbide cutting tools, Quickgrind has been working with medical equipment manufacturers to develop optimised tools and machining strategies to great effect.

At our headquarters in Tewkesbury, we use the latest ANCA multi-axis grinding machines as well as the Walter and Alicona inspection machines to develop bespoke tools, which we test and continually improve by machining parts on our state-of-the-art MAZAK 5-axis machine. We then run prove-out trials at the customer’s factory where our application team further develop the machining strategies to produce cycle time savings of 60% or more.

As the worldwide market continues to grow for replacement femoral knee joints, we work tirelessly at our in-house Technical Centre to identify areas of the production cycle for numerous parts whereby we can greatly reduce cycle times by applying our expertise and know-how. Two main areas that we have identified as key factors that are causing companies in this industry much headache and despair are the composition and machining of the base material and the other is the high finish requirements for these parts.

Demand for orthopaedic implants is growing as life expectancy continues to lengthen. An ageing population suffering from arthritis and osteoporosis together with trends towards higher body weight and obesity result in high and continual growth for medical implants. Nowhere is this more evident than in the knee and hip replacement segment. Manufacturers of these components have high demands placed upon them to ‘scale up’ production without over increasing the price per part. Due to the high stresses, the implants have to endure during their lifetime, there has been a tendency for R&D to venture toward the growth of biocompatible materials – this brings an entirely new challenge to engineers machining the components.

The metallic materials need to be hard-wearing and require high-quality surface finishes to enable the plastic parts to achieve their life expectancy of 20 years or more. The hard-wearing metal parts with plastic cushioned between them require high levels of absolute smoothness to protect against wear and early failure. For example, in replacement knee joints this means the femoral component and tibial tray must be machined and polished to the highest levels achievable.

Here, we are concentrating on femoral knee implants due to the high demand placed on the cutting tools to machine materials such as titanium and cobalt chrome. These materials are chosen due to their ability not to react with body tissue whilst being relatively lightweight.

The machining processes

To machine the femoral component, we use the following ranges with specific recipes of tool material, geometry and coating to ensure trouble-free machining and long tool life of both the new tool and the remanufactured tool that is a service provided through our QuickEdge service.

The machining process of the femoral component requires CNC machines (typically with a 5th axis or at a minimum a 3-axis machine with fourth axis capability) to rough, semi-finish and finish the part ready for polishing. The polishing process is time-consuming and removes the machining marks – but this is a labour-intensive high-cost process. Therefore, the machining process should provide a high level of surface finish leaving less material to be removed during this process. This greatly influences the overall production cycle time and therefore manufacturing costs. 

The tool that we have applied and has subsequently proven invaluable in this process is our Mirage Super end mill for roughing. The other tool of choice is our highly innovative Eliminator barrel tool which is a direct replacement for ballnose endmills.

The roughing process is time-consuming and creates a high level of tool wear. At Quickgrind, the composition we have created in our Mirage Super end mills provides high resistance to tool wear and it also enables high metal removal rates.

With the right CAM software, we can eliminate the use of ballnose endmills to semi-finish and finish the parts as these are time-consuming. Until the introduction of barrel tools, this was the only way to achieve the required pre-polishing finish. Now, we show two examples that are our main stay with customers.

Here we show some of the tools we have developed that are proving phenomenally successful. These products are giving our customers a high ROI. However, this is not all we can do for the customer. Through our ‘Infinite Possibilities’ programme, we enable our customers to never be restricted in determining the best and most efficient tool for their particular parts and processes. By streamlining the process and reducing the number of tools used, we have been able to bring about great savings for our customers and with our ‘never-stand-still’ ethos, we continually look for improvements. Quickgrind will be exhibiting at the Manufacturing Solutions Ireland exhibition in Limerick on the 15th and 16th of June, to find out more please contact Quickgrind.

MACH was a stroke of Genius for Carfulan

A record-breaking return to exhibiting at MACH 2022 meant it was a successful show for the Carfulan Group as interest continues to grow in its manufacturing technology.

Hundreds of visitors stepped onto the Carfulan Group stand at the NEC in Birmingham with the Group collecting a record number of enquiries from its four companies, as well as completing a number of deals for machines on the stand.

After a four-year break from MACH due to the pandemic, the stand was the Group’s biggest and best yet as it wowed visitors thanks to outstanding technology, brand new machines, first-class hospitality and an exciting competition to win two VIP F1 British Grand Prix tickets.

OGP UK presented its world-leading range of multi-sensor metrology machines, SYS Systems showcased the Stratasys F900 for the first time ever in the UK, ZOLLER UK unveiled the newly-redesigned Genius tool inspection system and VICIVISION UK launched the brand-new PRIMA turned part measurement machine.

A gripping debut

The MACH debut appearance for Grip-Tec Ltd proved a resounding success as its new range of workholding and clamping technology from 5th AXIS caught the attention of show visitors. With an extraordinarily diverse portfolio that ranges from self-centring and double-station vices, zero-point clamping, dovetail clamping alignment pallets, multi-position mounts, pull studs and accessories, jaws, replacement parts and automation solutions – the stand was a hive of activity throughout MACH week.

One product that drew interest from show visitors was the X-Series of self-centring vices. The original two-bolt SHCS jaw mounting and dowel pin configuration has now been enhanced in the latest generation of V562X and V510X vices that feature a keyed truck and a 4-bolt SHCS jaw. Alongside the X Series at MACH was the Rocklock. Designed and built for all 3, 4 and 5-axis machines, the Rocklock quick-change system provides a standard mounting pattern that allows end-users to easily move vices, fixtures and tooling from one machine to another with minimum setup time. Built to fit upon multiple machine tools, the Rocklock standardises setups and eliminates the need to build custom adapters and sub-plates for every new job. Another crowd-pleaser at MACH was the Dovetail fixtures. The perfect complement for manufacturers that want to clamp large components with a small workholding device, the dovetail holders provide excellent rigidity.

New PCD line for HSM

With the global launch of the new ADDFORCE brand from Tungaloy, the cutting tool manufacturer has introduced its new TungRec DX110 Series of PCD insert grades for machining aluminium alloy components.

The Tungaloy TungRec milling range has long been an exceptional performer with its tool bodies and insert geometries, but now, this line is set to take aluminium machining to a new level with the new DX110 PCD insert grade. Developed for the finish machining of ISO N materials, the new DX110 grade incorporates an ultrafine micrograin structure to demonstrate exceptional cutting edge integrity. This ability to maintain edge sharpness over a prolonged period ensures that end-users benefit from impressive tool life and extended periods of unmanned running.

The new DX110 inserts are the first PCD solution to be incorporated into the TungRec line, offering existing TungRec users the facility to enhance aluminium machining capabilities with existing tool bodies. At present, the PCD inserts are available for TungRec 11 size toolholders, offering the facility for improving small diameter milling tools where vibration and excessive tool overhang are commonplace.  Suitable for aluminium components in the aerospace, automotive and general subcontract sectors, the DX110 insert grade and the TungRec toolholders for insert size 11 provide manufacturers with an indexable cutting tool solution from as small as 12mm diameter. With tool diameter bodies extending up to 100mm diameter, this new arrival to the TungRec range complements the existing TungSpeed-Mill PCD Series.

Funding support races forward at MACH

MACH 2022 marked the 10th consecutive occasion that Close Brothers Asset Finance has participated in the event. To draw the crowds, the company had a BAC Mono sports car on its stand – as the company is a client of Close Brothers Asset Finance.

Regarding the event, Steve Gee, the CEO of Close Brothers Asset Finance’s Industrial Equipment Division said: “The event has a broad agenda and addresses a wide variety of topics, from the sector’s role in helping meet our climate commitments, the development of the digital factory, new automation solutions to connected manufacturing processes, power by the hour and improving production processes. We know we have a role to play in helping firms meet future demands and we are looking forward to doing so.”

In 2015, Close Brothers launched an SME Apprentice Programme to help manufacturers secure the skills they need for future growth and to recruit the next generation of engineers. Each year, Close Brothers pays for 20 apprentices, contributing 50% of the apprentices’ wages in the first year and 25% in the second year. Additionally, Close Brothers cover all of the training costs. Further support is also offered for those on degree apprenticeships.

“We know from experience that SMEs often need assistance to take on apprentices, so we designed our programme to help with the specific issues they face. We believe the scheme has made a real difference to the business results of participating SMEs,” added Steve.

MecWash cleans-up at MACH

The MecWash team had a record number of enquiries following their return to MACH where they showcased the brand-new MWX300 aqueous parts washing system. 

“MACH is the UK’s biggest manufacturing exhibition. After the enforced hiatus due to Covid-19, it was fantastic to hear the buzz of business, see familiar faces and meet new connections from across the sector,” said MecWash Managing Director John Pattison

The MecWash team were delighted to receive enquiries from long-term, established customers as well as from a range of new business contacts. There were also great opportunities to talk to some of the bright young student talent in this sector. The range of sectors represented by both existing customers and new enquiries covered everything from hydraulics and aerospace to medical, automotive and motorsport sectors as well as a barista-style coffee machine and fasteners manufacturers.

The compact MWX300 was very popular and stand visitors were impressed with the high specification washing processes that include ultrasonic cleaning, high flow washing and internet connectivity packed into the small footprint. The larger MWX400, which has already proven highly successful in markets around the world, was also on display.

John Pattison comments: “Seeing first-hand how other exhibitors and manufacturers showcase their systems is great inspiration and motivation for us to continue innovating as we seek to provide world-leading component cleaning solutions!” 

British HealthTech is well set as surgery flood gates open

SMEs make up the vast majority of HealthTech companies, a sector that employs over 138,000 people. While more elective surgeries will take place now the pandemic has passed, the UK needs to invest more in R&D to ‘keep pace with the global innovation race’*.

By Will Stirling

Medical device manufacturing is a very entrepreneurial and fluid industry within the broader life sciences industry. The products are highly engineered, increasingly with digital or ‘smart’ functions, and often high margin – although this depends on the product. It also has a high number of start-ups, mergers and acquisitions. Reasons include that health (for many) is not optional, plus the attraction of a reliable, deep-pocketed prime customer, the NHS, and the sector covers so many disciplines of engineering and technology. Then there is population growth, and that technology reduces barriers to entry.

It has a strong forecast too. The Association of British Healthcare Industries (ABHI), the industry body, says there is an increasing amount of ‘other’ technology i.e., beyond mechanical and electronic, essential to the delivery of modern healthcare today, that will remain vital in 10-years. The UK population is predicted to both grow and age, from 65.6 million in 2016 to over 74 million by 2039, and older people need more medical treatment.

The government defines ‘Core Med Tech’ as all businesses whose primary business involves developing and producing Med Tech products, ranging from single-use consumables to complex hospital equipment, including digital health products. This might be more broadly defined as HealthTech, covering the devices and machines and the digital platforms that add value to these. HealthTech is the largest employer in the life sciences sector, employing 138,100 people in 4,140 companies, with a combined turnover of £27.6bn (Source: ABHI). The industry has enjoyed growth of around 5% in recent years and it is dominated by SMEs.

Digital medical devices combine the older disciplines of device design and manufacture with sensors, data capture and presentation for monitoring, and increasingly use artificial intelligence. The biggest trend is the rise in companies that bolt on digital services to the physical product that can be sold as a product or subscription service.

The investment made in recent years has given British medical device (or Med Dev) companies a boost. As well as albeit changing – demand from the NHS, private hospitals and exports – manufacturers, today can harness machine learning, nanotechnology, materials such as graphene, simulation software and DNA decoding technology.

Challenges

One problem with more Med Dev growth is that British R&D spending, which totalled £38.5bn in 2019, is among the lowest in OECD countries as a percentage of GDP – just 1.7%. The strategy aims to increase public and private R&D investment to 2.4% of GDP by 2027, and this includes raising annual public investment in R&D to £22bn, from nearly £15bn in 2021-22. There is also a big challenge to increase elective surgical procedures after Covid sucked out hospital capacity with finite human resources, especially surgeons and nurses.

MTD looks at some of the exciting British medical device and HealthTech companies.

JRI Orthopaedics

Arthroplasty implants are a substantial segment of the medical devices sector and have faced challenges from both funding of the NHS – its primary customer – and Covid. The pandemic created a huge backlog of elective surgical procedures, and fierce competition has pushed the unit price of implants down over the past decade or so.

JRI Orthopaedics, an arthroplasty company in Sheffield, designs and makes a range of implants that include hip and knee replacements, shoulder products and orthobiologics. Pre-Covid, NHS funding restricted the throughput of elective operations, limiting orders for JRI and other implant companies, and then Covid increased the waiting list massively. Frustratingly the demand, the patient need, is huge. “One stat showed that if the NHS worked at 120% it would take six years to return to the position the industry had in 2019,” says head of sales, Gareth Horton. “That position has slipped again because it is not working at 120%; regional differences aside probably it’s working at 80% at best.”

The GIRFT Report recommended the NHS provide centres that specialise in arthroplasty operations like hip and knee replacements, where surgeons could focus on these procedures and complete four to five joint replacements a day. This has not yet materialised and the rate is at two to three operations a day, so the backlog persists. “Reasons for slow throughput are that there are so many more Covid protocols in theatre to work through and staffing levels have fallen.”

Despite this, the surgery pipeline is picking up in the UK and abroad ‘post-Covid’ and JRI Orthopaedics is well placed. It offers both a customised and standard range of medical implants, items at industry-certified standard sizes that surgeons can pick off the shelf, and parts

designed as one-offs. “The NHS needs a credible alternative supplier to the very large global companies whose model is suited to high volume, standard products only – that does not suit all cases,” says Gareth. Materials used are typically stainless steel, titanium and cobalt chrome. JRI employs 90 people, exports products globally and is now part of the AK Medical Group.

CMR Surgical

This Cambridge-based company manufactures surgical robots and is flying high with the Versius Surgical Robotic System, its flagship product. In June 2021, CMR completed a £600m Series D funding round (co-led by Softbank Vision Fund 2 and Ally Bridge Group), notably the biggest-ever private MedTech raise. That money is being put to good use – in 2021 CMR announced plans to build a new global manufacturing hub in Cambridgeshire, for completion in 2023. The new facility will span 7,044.8sq/m floor space and employ up to 200 skilled employees, initially from production, quality, manufacturing engineering, supply, operations, and logistics, with 100 new jobs expected to be created between 2023-2025. 

Since the start of 2021, the Versius system has been launched in Germany, Australia, Italy, Poland, Egypt, Pakistan and Hong Kong, joining other markets across Europe, Asia and the Middle East. Versius has also been introduced in Wales as part of a ‘first-of-its-kind’ National Robotic-Assisted Surgery Programme in partnership with NHS Wales and LifeSciences Hub Wales.

Brandon Medical

Brandon Medical recently won a Queen’s Award for Innovation, for its Intelligent Theatre Control Pane (iTCP), a smart communication and control system for operating theatres. iTCP is the first operational technology (OT) control panel that talks to the building management system and the operating theatre equipment, using smart building protocols to include Operating Theatre Smart Integration (a form of IoT). The system is 100% designed and manufactured in the UK. Hospital operating theatres have until now been disconnected from the Building Management System – the company says the iTCP is creating the smart operating theatre, integrating acute care areas into the digital hospital.  The modular concept of iTCP allows for de-risking operating theatre projects, and it has an in-built capacity to absorb and connect with new clinically driven technologies and equipment not invented yet. 

“Brandon Medical’s unique intelligent Theatre Control Panel provides clinical staff with an intuitive user interface to easily control the suite of operating theatre equipment and detailed technical information to hospital engineering teams for routine maintenance and condition monitoring,” says Keith Jackson, CEO and visiting professor at The University of Sheffield.

Gendrive

A University of Manchester spin-out, Gendrive’s bedside intelligent monitor identifies whether a critically ill infant has a gene that could result in permanent hearing loss if they are treated with a common emergency antibiotic.

Patients admitted to intensive care are usually given an antibiotic called Gentamicin within 60 minutes. This drug is used to safely treat about 100,000 babies a year, but one in 500 babies carries the gene that can cause permanent hearing loss. The new test means that babies found to have the genetic variant can be given an alternative antibiotic within the ‘golden hour.’ The test could save the NHS £5m annually by reducing the need for other interventions, such as cochlear implants.

Investment in Med Dev

• Ortho Clinical Diagnostics UK will expand its biological diagnostic product lines at its Pencoed site in Wales.

• Randox Laboratories, famous for its Covid-19 testing kits, is building a large new manufacturing facility in Northern Ireland with state backing.

• Piramal Healthcare is undertaking a facilities upgrade at its Morpeth site in Northumberland, where it develops, manufactures and packages a broad range of medical products.

Tyrolit shines at MACH

Tyrolit had a very busy and successful week at MACH 2022, with over 300 enquiries to the stand across the week. Showcasing over 120 individual products on the stand, Tyrolit exhibited the latest range of innovative products and services.

With specific areas for industries such as medical, automotive, aerospace, tooling and gearing – providing visitors with extensive insight into the dedicated areas of expertise. The modular assistance system ToolScope was also demonstrated live on the stand, with an interactive display, introducing visitors to the digitalisation of grinding technology; proving of great interest to those looking for a comprehensive system solution.

In addition to displaying the latest in grinding and abrasive technology, Tyrolit launched the NEW Competence in Surface Conditioning and Sunburst Bristle Brushes at MACH. Now being able to offer a large range of Non-Woven Surface Conditioning products, following the acquisition of Bibielle (Italy), Tyrolit can provide customers with a complete solution. Interest in the new Bristle Brushes soared, with an extremely limited number of other suppliers for such products on the market, this has been an exciting time for the business.

ANCA to showcase agility & innovation

ANCA will showcase its latest innovations at the GrindingHub show in Stuttgart in Hall 10 Stand C51. “Automation and digitization are at the centre of this display. We are showing Industry 4.0 solutions that fit with the context and targets of our customers, be it small, mid-sized or larger companies,” says Martin Winterstein, Sales Manager for Europe. 

The company will launch its CPX in-process OD measurement system, a quality control system that monitors and controls the OD of ground blanks within batch production. Batch grinding on a CPX with high material removal rates and to tight tolerances is a basic function of the machine, the OD measurement system takes it further by utilising the SPC feature that comes standard with the OD software. 

ANCA’s Integrated Manufacturing System (AIMS) streamlines manufacturing and connectivity. With ANCA and AIMS, customers can achieve continuous, unattended production that reduces non-productive machine time with smart automation that offers connectivity across the whole factory. The technology considers a factory as a single machine, rather than separating it into different elements of design, blank preparation, grinding, laser marking, washing, packing and shipment. This concept brings together one ecosystem and builds it to be as efficient as possible. 

The GrindingHub demo consists of the AutoSet preparation station, as the main operator interface. Jobs scheduled for production are downloaded through the AIMS server to the AutoSet station and are prepared for production, pallets are loaded with blanks for automatic process and the AutoFetch AMR (Autonomous Mobile Robot) responsible for transfer between processes replaces operators carrying pallets or individual tools between machines. The AutoFetch robot will transfer full pallets with blanks to the respective grinder, pick up an individual tool from a grinder for out-of-process measurement and compensation and then pick a pallet of finished tools and transfer to finished goods. 

ANCA will also show its RFID technology with the LaserUltra closed-loop measurement and barcode reader that will be demonstrated on the FX7 Linear platform. The FX7 Linear machine will also be fitted with a pop-up steady, AutoStick, auto wheel qualification and iView. 

Driven by the automotive industry’s electrification and the general rise of e-mobility, the demand for skiving cutters has seen 30% year on year growth. The GCX Linear will provide a complete solution for producing skiving cutters, shaper cutters and the regrinding of hobs.

Rapid CNC metrology enables proactive quality control

Medical injection moulding specialist Polymermedics will increase the inline measurement of customers’ components, after investing in a new Smartscope CNC 500 measurement machine from OGP.

The automated, multi-sensor system is the latest in a series of metrology investments at Polymermedics’ Cornwall headquarters, increasing capacity and precision to accommodate new medical, dental and micro moulding projects while retaining ISO:9001 and ISO:13485 quality processes.

Quality Manager Derren Blewett explains: “We make about two billion parts a year – and everyone needs to fit very precisely – whether it’s to ensure a tight seal, or to match the profile of a dental file. Our quality lab has been working at full capacity, with shifts around the clock.”

The new machine will work alongside Polymermedics’ existing OGP MVP-300 unit, increasing capacity while adding a new ability to rapidly laser-scan surface profiles.

“We’ve always been pretty obsessive about making sure validation measurements are spot-on,” Derren continues. “The new Smartscope will take that accuracy and repeatability to another level.”

“It’s also extremely fast – with the size to scan several parts at once – and the resulting capacity means we can now do more inline measurement, follow minute trends in the dimensions of the parts we produce and be even more proactive about ensuring quality on our clients’ behalf.”

At the top  of OGP’s Smartscope range, Derren describes the CNC 500 as the ‘Rolls Royce of metrology machines’. It combines optics, laser  and Renishaw TP-20 probe measurement, allowing precise, repeatable readings and rapid surface data collection – perfect for companies like Polymermedics, who produce a high volume of parts meeting demanding accuracy tolerances.

Importantly, the data collected can be exported in several easily readable formats – including 3D CAD geometry – making it easy for Polymermedics to spot trends in inline testing over time, and understand how clients’ moulding tools are performing as production volumes increase.

Perfect for micro moulding

With a growing micro moulding order book, Polymermedics will particularly benefit from the enhanced 2µm accuracy level provided by the CNC 500’s laser and probe sensors, while the eight LED ring light surrounding the optical edge imaging gives extremely repeatable results within just 2.5µm.

OGP UK Sales Manager Graham Shaw spent two months working with Polymermedics to specify the ideal machine for the job. He believes having three kinds of sensor in one unit will prove crucial as the company continues to grow.

“We worked hard to find a solution that would be as future-proof as possible. The large bed size in particular gives Polymermedics real flexibility: they can now measure parts up to 500mm, while the option to accurately scan multiple smaller parts at once is perfect for their growing micro moulding business. The laser will prove invaluable for verifying the surface quality of their parts, too.”

“I’ve known Polymermedics since the company was founded; Derren, Dave, John and the team are really easy to work with. It’s a close relationship, and we’re always happy to give them whatever support they need to get the job done for their customers.”

Best MACH Ever!

Recognised as an industry leading CAM/CAD system for everything from 3-axis to complex 5-axis machining, OPEN MIND Technologies demonstrated exactly why at MACH 2022 with its latest hyperMILL^® Version 2022.1. 

Commenting upon the MACH show, OPEN MIND UK’s Sales Director Ken Baldwin beamed: “We almost received too many leads to deal with! The show was the best MACH we have ever done and out of the hundreds of leads we received, there are upward of 70 companies that want to purchase hyperMILL^® straight away. We had six demonstration pods on our stand and the team was extremely busy all week with queues for demonstrations every day.”

“MACH 2022 really was a tipping point for the OPEN MIND brand in the UK. We have been building the brand and the technology has been edging further beyond the realms of our competitors for some years; but at MACH, the visitors were purposely seeking us out. Our visitors were a combination of businesses that had recommendations to buy hyperMILL^® from customers, suppliers, colleagues and the machine tool companies that were fellow exhibitors at MACH. With MACH being the first major UK show since the pandemic, visitors came with an intent to buy – and for those companies investing in new machinery, they were subsequently directed to our stand by the machine tool suppliers. This exemplifies not just our relationship with the machine tool vendors, but also the ability of hyperMILL^® to help engineers get the most out of their machine tools. Over the next couple of weeks, our team will be collecting orders from stand visitors that were immediately sold on hyperMILL^® whilst other manufacturers are keen to step away from existing CAD/CAM suppliers and move to OPEN MIND. MACH was a resounding success and our team will be busy for months after such a successful show.”

The latest edition of hyperMILL^®, Version 2022.1 is packed with an abundance of innovations for enhancing productivity, performance and programming times for components produced on machining centres – but this latest version also incorporates a wealth of new features for its turning cycles. It is for this reason, so many show visitors made a beeline for the OPEN MIND stand at MACH.

WaldrichSiegen uses VERICUT to perfect its processes

Manufacturer of CNC machines since 1840 and available in the UK from McDowell Machining Technologies, WaldrichSiegen is a prime example of sustainability due to the company’s ability to adapt to changes by investing in new, innovative technologies. Moving from the era of the steam engine to Industry 4.0, the company has maintained its core DNA.

WaldrichSiegen is defined by two words: accuracy and performance. The company specialises in large machine tools and its customers are mainly manufacturers of heavy marine engines, crankshafts and turbine rotors – that are increasingly demanding. That’s why WaldrichSiegen has invested in future-oriented technologies such as NC simulation with VERICUT to not just meet the needs of its customers but to surpass them. For them, the use of VERICUT software makes it possible to be more efficient and profitable from the start.

The largest machine in the world is built in Burbach

Since 2009, the 350 employee company has been using VERICUT for CNC simulation, G-code verification and optimisation. With the production simulation of the NC data, i.e. the machine code, WaldrichSiegen recreates the real machining situation with a ‘virtual processing machine on the desk’. This is done before even cutting the first chip. VERICUT simulates the original NC G-code after the post-processor is executed. This then detects program errors such as fast-forward errors or contour violations before any actual manufacturing.

“With VERICUT, machine collisions can be avoided, complex clamping situations can be safely retracted or cycle times can be reduced while at the same time increasing tool life,” says Christian Apel, Sales Representative of CGTech Deutschland GmbH. 

This is particularly appreciated in large-scale machine tool construction, where process reliability is the be-all and end-all. To grasp the significance of error-free machining, it is worth taking a look at the key data of the world’s largest horizontal lathe, built after the customer’s ‘Go’ in 2009 at WaldrichSiegen. The machine has a 7m turning diameter, 25m workpiece length and more than 350 tonnes maximum workpiece weight. Previously, the company produced a lot of waste and had to do endless machining tests. Today, VERICUT makes it possible to safely speed up NC programs, improve part quality and reduce machining times.

More streamlined processes, better products, happier customers.

WaldrichSiegen not only uses VERICUT simulation software to streamline its manufacturing processes but that of its customers too. Indeed, the company wants to use digital transformation and its integral elements such as the digital twin in VERICUT, to develop new fields of activity and to transfer real added value to customers.

For example, by integrating customers and partners into the company’s value creation processes at an early stage. Timo Hees, an Application Technician at WaldrichSiegen, says: “When a customer orders a machine, we often carry out studies upstream so that we can determine and evaluate subsequent machining times at an early stage.

“It’s well thought out and well done. WaldrichSiegen simulates the customers’ machining in VERICUT, to demonstrate the machining and process times for the customer’s parts, even before the actual machine is installed at the customer’s premises. This makes it possible to make valid business decisions at all levels.”

Timo Hees explains: “VERICUT is an integral part of the project. The machine is then made available to the customer with the kinematics developed in collaboration and tested by WaldrichSiegen. This is the only way to ultimately guarantee that all functions can be performed appropriately so that the customer can already perform their simulation and check internally in VERICUT if everything is in line with what they had planned.”

“It’s in the millions, which is why we only have one trial.”

According to management member Stefan Tschersche, the advantage of such an approach for WaldrichSiegen’s customers is obvious: “With VERICUT, we ensure that the machining is simulated beforehand as close as possible to reality to avoid damaging the part and the machine.”

Collisions would also be fatal given the size of the part and the machine tool. Stock material alone can cost several hundred thousand Euros, sometimes more. “This can go up to several million, which is why we often only have one test,” confirms Stefan Tschersche.

The large machine tools at the Siegen production site are used, among other things, in the production of diesel engines, cogeneration plants, turbines, general mechanical engineering, the energy sector as well as in defence and nuclear.

Decades of experience to develop high-performance solutions.

WaldrichSiegen draws on decades of experience to develop high-performance solutions that are perfectly suited to a wide range of applications. WaldrichSiegen is part of the HerkulesGroup, which has more than 1500 employees worldwide. A specialist in the development and production of large machine tools, it offers its customers complete high-precision machining to make the most complex parts. Beyond all the performance data, HerkulesGroup’s companies also offer customers absolute added value with their machines, considering life-cycle costs from the moment of construction. Thus, the machines are energy efficient, easy to maintain and repair, and are of the highest quality down to the smallest detail. 

For more than 180 years, WaldrichSiegen has known that continuous innovation is needed to create industry-leading trends. Currently, the company is showing great interest in using the FORCE module. WaldrichSiegen wants to optimise the processing times of its clients’ complex projects. FORCE is a physics-based NC program optimisation software module that analyses and optimises cutting conditions throughout the NC program. It provides the most efficient NC program based on material, cutting tool and machining conditions. These results are considerable time savings and improved cutting tool life.

Bowers Group enjoys successful MACH

Bowers Group is celebrating the success of the MACH Exhibition following a 4-year hiatus due to the Covid pandemic. The Bowers Group stand was exceptionally busy with high levels of interest in the full product range. 

Bowers Group UK Sales Manager Ryan Kingswell said: “It was absolutely fantastic to be back at MACH 2022. Not only has it been a great opportunity to re-engage with some customers we haven’t seen for some time, we’re also very much looking forward to following up with new customers to explore solutions we’ve discussed on the stand.” 

“We’re delighted with visitors’ reactions to both our new digital external micrometer, the DigiMic, and the popularity of the live demo of the Sylvac F60 Optical Scanning system working in conjunction with a Universal UR5 robot, fully illustrating the capabilities of Industry 4.0. The show has been an amazing success; we’re delighted that MACH is back with a bang!”

Visitors were also very interested in the variety of standard and bespoke solutions designed and developed by the Bowers Group application gauging team. Many people visited the stand to discuss their own specific measurement requirements, including solutions for the measurement of grooves, threads and splines which are fully compatible with Bowers XT range of digital bore gauges and include optional Bluetooth.

Expect more from industrial suppliers

National supplier of metalworking and maintenance, repair and operations (MRO) products and services, MSC Industrial Supply Co. UK is exhibiting at MACH in Hall 6 Stand 310.

As a supplier of over 120,000 metalworking, safety and MRO products, MSC will display a deconstructed aerospace engine. The jet engine assembly showcases the complex mix of product applications from a variety of aerospace-grade alloys that are typically produced by aerospace manufacturers. Along with supplying products, MSC supports aerospace manufacturers producing similar components with its engineering expertise. 

MSC’s Engineering Team will be on the stand throughout the event showcasing real-world examples of how MSC has partnered with manufacturers to improve their processes and manufacturing capabilities. MSC sees its role as more than a high-service level distributor of industrial products. That’s why MACH visitors will also learn how its partner, Next Gen Makers, can support engineering and manufacturing businesses on how to better plan for attracting and retaining apprentices. Completing the stand is MSC’s ControlPoint; an inventory management solution for the consolidated purchase of tooling, PPE and consumables using on-site vending machines. The vending machines allow customers to have 24/7 access to products without having to leave their factory floor.

Engineering precisely what you value

At MACH, Starrag UK will be showing the company’s latest machines – the Bumotec 191neo mill-turn centre for small, complex parts. This will demonstrate how Starrag’s ‘Engineering precisely what you value’ slogan continues to help companies achieve rewards when using Starrag’s product ranges that include Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP and Starrag.

Targeted at users in the medical, luxury goods and micro-mechanics industries, the new seven-axis Bumotec 191neo can accommodate bar up to 65mm diameter, and with up to 90 tools and an intuitive HMI control system, the machine will enable users to achieve a new standard in high added-value small component production in a single set-up. 

Another example of how Starrag’s success has been built on providing machining solutions for specific market demands is the affordable Heckert H65 machining centre, which was announced last year. Starrag’s new lower-cost Heckert H65 compact horizontal machining centre adds a new dimension to heavy-duty 4-axis machining with unrivalled performance for a machine of its class. Occupying just 24m², the H65 offers machining speeds up to 30% faster than comparable models and can increase output levels by 80%.

With X, Y and Z axes of 850 by 1,020 by 1,000mm and 630 by 500mm twin pallets that can accommodate loads of 1.5 tonnes, this latest addition to Heckert’s compact H range provides traverse rates up to 80m/min and a standard spindle speed of up to 10,000rpm from its 60kW hollow shaft HSK-A100 spindle. 

Aerospace, medical and luxury goods are core industries for Starrag – but so too are energy, transport and industrial components and Lee Scott, Starrag UK Director for Sales and Applications says: “Visitors to MACH from all these sectors may well be surprised, and pleased at how affordable and available many Starrag machines are.”