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.

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 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.

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.

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.

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.

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!” 

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.

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.

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.”

Cool Technology

Seeley International is a designer and manufacturer of evaporative cooling products and as evaporative cooling is becoming the most efficient option for cooling large areas – this will be showcased at MACH on Stand 48 in Hall 6. 

Traditional air conditioning may not even be an option in warehouses or industrial plants, as the capital and running costs would be extremely prohibitive. Most industries with high heat loads, such as printing, ceramics, glass, rubber or electronics, have no cooling system installed and this impacts the workers’ morale, productivity and health. In these examples, Direct Evaporative Cooling could be the right solution. 

Seeley coolers do not use any sort of chemical refrigerants to cool the air, just a pump to supply water to the wetted media where evaporation occurs. A small amount of electricity is required for the pump and the fan that pushes the air inside the building. Evaporative air cooling uses up to 87% less energy than conventional air conditioning. Indoor Air Quality (IAQ) is high on the agenda to maintain a healthy and comfortable environment. Seely products supply 100% fresh filtered outside air; so spaces are effectively being purged when coolers are being used, removing dust, dirt, allergens and airborne viruses. 

Perhaps you only have one or two small areas inside the space that need cooling. This is not a problem as ‘spot cooling’ can be achieved with Seely units.

Precision Honing

On Stand 310 in Hall 19, Mu-Tools will show the type Mu-HS1 single spindle and Mu-HS2 double spindle machines that have been developed to perform high precision honing operations.

The honing range starts at 0.6mm diameter up to 80mm with honing lengths up to 210mm, depending on the shape of the workpiece. All types of Mu-Tools honing tools can be used on these machines. The QR codes on the packaging boxes can be scanned and the detailed honing tool information can be transferred directly to the program. The machine software can analyse the data of each tool and display the state of wear of the tools at any time, indicating the number of parts machined per honing tool. The chassis of the Mu-HS1 and Mu-HS2 machines is identical and allows the machine type to be configured very quickly. In addition, reinforced elements have been integrated to connect an automatic workpiece loading system. 

The spindle has been developed by BBN Mécanique, a specialist in high precision spindles and the maximum speed is 8000rpm with a torque of 11.4Nm. The expansion system is integrated into the spindle and controlled by a micrometric screw system. Specific sensors are connected to the expansion motors as well as to the spindle motor. They allow the recovery of data on torque, heat and current to analyse the cutting forces between the tool and the material as accurately as possible.

The honing movement is carried out by a table coupled to a linear motor, allowing a 350mm stroke and a honing stroke of 210mm. Depending on the geometric defect in the workpiece bore, it is possible to set several honing strokes at different positions in the same program. The workpiece clamping systems can be mechanical or pneumatic.

Plotting a path to sustainability

Sustainability is coming to the forefront for all of us in business and personal life. Many important decisions going forward will have an impact on our environment, economy and society. Wogaard’s product focus and design team have a clear vision to encompass all the elements and provide oil and coolant solutions that optimise manufacturing processes and make them more cost-effective and environmentally friendly.

“At Wogaard, we like to say that we are in the business of saving oil/coolant costs, the environment and improving health and safety  – a lot of positive tick marks for any manufacturing business,” says Jason Hutt, Managing Director of Wogaard. “We realise sustainability will have a significant impact on people, society and the environment. So, the manufacturing industry needs to work hard to reduce its effect on nature and the climate.”

Wogaard’s flagship product, the ‘Coolant Saver’, was designed with cost-saving in mind, as it involves a solution to reclaim the good coolant from the swarf bin and return it to the machine for re-use. It has made a huge difference to many businesses since its creation. It enables companies to save money by improving efficiency, protecting the environment and reducing disposal costs by cutting down waste and keeping the work area cleaner by diminishing the amount of mess left in the swarf bin.

“Over the last decade, we have assisted hundreds of businesses in reducing the environmental impact of their manufacturing activities,” Hutt explains. “We want to support clients to make cost savings and improve their manufacturing processes, but together we have a bigger mission, which is to become more sustainable to support the environment. With thousands of units supplied globally, saving millions of litres of coolant every day, we are proud that we are achieving this and are focused on designing more products with this in mind.”

However, spreading the message of sustainability is not always easy, as Wogaard’s Managing Director explains: “We sometimes encounter negative mindsets when we talk to clients about sustainability,” Hutt says. “Therefore, we often find it more effective to highlight how much our products will save them in terms of money and resources first, and then mention that these savings are also good for the environment.”

The Coolant Saver executes its purpose so perfectly that it is impossible not to be impressed. And its impact on sustainability is clear for all to see, so it may be worth checking out at MACH on Stand 20-26. 

MecWash to reveal new system

MecWash is to introduce a brand-new aqueous cleaning system at MACH. The new MWX300 is the compact version of the MWX400. Designed for low volume specialist applications, the MWX300 delivers cleanliness standards perfect for the aerospace, electronics and medical sectors.

MecWash’s Managing Director John Pattison, explains: “Here at MecWash, we often have customers with exact cleaning requirements, and we pride ourselves on our ability to provide innovative solutions. “The new MWX300 is specifically designed to deliver the highest cleanliness standards from a small footprint, while also being easy to maintain with features that consistently top the list of our customer requirements.”

This latest introduction to the MecWash MWX range of industrial part washers feature enhanced functionality and improved accessibility for easy maintenance. It also utilises technology used in many smart machine tools to provide connected parts cleaning. MecWash will be showcasing the new technology on Stand 114 in Hall 18.

Sustainable technology for the factory floor

J&S Engineering UK will be exhibiting a range of green technology solutions for manufacturers looking to reduce their carbon footprint, improve their sustainability and save money at MACH.

On Stand 230 in Hall 18, J&S Engineering will show inspiring ‘green technology’ solutions for the factory floor with standalone machines and customised systems to enable the recycling, reclamation and re-use of waste materials from all types of metal swarf to cutting oil and coolant. The variety of equipment enables customers to consider different options for managing their waste materials and with incentives such as achieving up to 99% reclamation of cutting oil, up to 70% reduction in swarf volume, as well as worthy increases in metal swarf recycling value, the benefits are evident.

Some examples of systems customers could implement that will be on the stand are a centralised swarf vacuum system and a fully automatic swarf centrifuge from Fama Srl. A small portable briquetting unit as well as a standard static briquetting machine from Hocker Polytechnik, manual swarf centrifuges from Rimann AG as well as swarf vacuums from Siebec/Sofraper.

Alongside these, J&S Engineering has developed and manufactured an innovative range of part handling and bar chamfering machines. These will also feature at MACH 2022 with exclusive launches of new models from both ranges. Oil and coolant reclamation is a key feature of the part handlers, providing more incentives and opportunities to be ‘green’ when safely collecting finished components.

Third trade fair appearance at MACH for Grob

Following its debut in 2014, the Grob Group will be exhibiting for the third time at MACH on Stand 211 in Hall 19. In conjunction with Guhring, Grob will demonstrate the machining of a steel component on a G550 – Generation 2 machining centre. 

The latest Generation 2 horizontal 5-axis universal machining centre will showcase a die and mould component highlighting the maximum tool length available on a Grob. The machine will have the pioneering GROB4 Pilot control system and is supplied with a 16,000rpm HSK-A63 spindle with 206Nm of torque and an output of 32kW.

The second-generation machine is characterised by a modern design and some new assemblies and thus provides a whole range of advantages for customers. The G550 – Generation 2 has high dynamic performance and stability as well as a narrow design and a marked reduction in chip-to-chip time. The maximum tool length has been increased to 700mm and the number of HSK-A63 tools has been increased to 137. Like its little sister, one of the impressive features of the G550 – Generation 2       is its ergonomically favourable tool-loading point at the operator’s end. 

The 5-axis universal machining centre is an optimally designed machine for the wide range of requirements of individual manufacturing sectors. Now available in the second generation, Grob engineers have integrated several technical innovations and advancements that substantially improve the universal machines. Due to a repositioning of the tool magazine, Grob has reduced the machine width from 2.45m to 2m, thus achieving a significantly smaller machine footprint. Furthermore, the tool capacity now comprises 60 slots, which can easily be increased to 120 slots with the double disk machine.

Safer and more productive materials handling

Irish material handling specialist Combilift will be at MACH on Stand 170 in Hall 6 to showcase some of the new models it has developed. The ability of many of Combilift’s products to save space in storage and production areas proved to be invaluable during the pandemic when manufacturers needed to keep up production levels whilst ensuring the social distancing of employees. 

The latest innovations are packed full of features that have become a Combilift hallmark. In line with demand for cleaner, greener operations, the focus in Combilift’s R&D department has been on expanding its electric range. The new multi-directional Combi-XLE launched in autumn 2021, combines quiet, emission-free operation with powerful performance and lift capacities up to 5 tonnes for tough working environments. It features high ground clearance, large cushioned front and rear tyres and a spacious cab, allowing smooth operation on semi-rough terrain whilst offering a high level of driver comfort.

A further innovation is the new Aisle Master-OP (AME-OP) – a stand-on electric-powered model that combines the advantages of a narrow aisle articulated forklift and an order picker for versatile operation in storerooms and warehousing facilities. The main feature is its low-level step-through operator compartment with a height of just 280mm. Convenient, single-step access from both sides of the truck speeds up order picking compared to the operator having to get in and out from a seated position. 

Airbench to clean up

At MACH, AirBench will be exhibiting its downdraught bench, modular dust extraction booth system, central coolant mist extraction system and the machine-mount smoke and mist extraction unit on Stand 630 in Hall 20. 

For machine tool applications, AirBench will demonstrate its AOF series of machine mounted smoke and mist extraction systems that support a single machine tool by extracting coolant mist and smoke. Utilising a long-life final filter and a unique wind-shear filtration mechanism to increase filter life, the self-contained coolant mist and oil smoke filter is suitable for most machine tools with extraction rates up to 2400m³/h. The multi-layer final filter captures fine particulates and depending on the application, two filter options are available with finer filtration available for oil smoke. The conical main filter coalesces large particles on impact and then uses the wind shear principle to separate finer mist with further separation in the internal mesh layers. The final filter in this system has a lifespan of up to 3600 hours, making it ideal for most machine shops. 

Complementing the AOF at MACH will be the OMF central coolant mist extraction system. The OMF collects coolant mist from CNC machine tools and can be attached to single or multiple machines with up to 4000m³/h capacity. The OMF units are configured to connect to Jacob’s rigid clipped ducting for leak-free installations and ensure that the work area remains mist free, collecting particulate and providing the operator with visibility of the work area whilst preventing airborne mist from affecting the workshop

Alongside this will be the VertEx modular dust extraction booth system. The VertEx booths can be built from modular components to create dust extraction booths as large or as small as required. Assembly is quick and simple and reconfiguration is also a straightforward task. VertEx booths use VertEx VA dust extraction units to collect dust and VB booth components to form full enclosures. Dust extraction is an essential part of your COSHH compliance requirements and finding an effective and suitable solution can be a challenge. With the VertEx system, AirBench ensures that manufacturers meet their compliance requirements whilst providing a clean and safe working environment for employees.

For workstations where dust is commonplace, AirBench will also be demonstrating its range of downdraft benches. The air benches are high air volume, low-velocity extraction systems that provide a demonstrable working solution to a wide range of dust and fume problems. All products are built to order in the AirBench factory located in the East of England to short lead times. With a complete range of models that include the FX, FPW, BD, RP, FP, FPK and FN models, AirBench can provide solutions to specific problems using standard modular components and filter sets.

MMMA ‘Metalworking’ village

The Metalforming Machinery Makers Association (MMMA) will be hosting a specialist Metalworking exhibition within MACH to provide its members with an opportunity to show off their skills, services and technologies to visitors. Within the village, visitors will be welcomed to call on each member stand to explore what is available and how it could improve production, win more orders and increase profitability.

The MMMA members exhibiting at MACH will include Bruderer UK, Esprit Automation, Cotswold Machinery Sales, Worcester Presses, Schuler UK, TMA, Roemheld UK, Industrial Clutch Parts, Kaller Gas Springs, Press Techniques, Helm Instruments, Qualimach, Pressform Machinery, Decade Monitoring, Group Rhodes, Formit, Raybould Machine Tools ltd, Aida SRL UK, OSA Systems, CIDAN Machinery UK, Midland Power Press Services, Orlikon-Belzers and Ortlinghaus.

Some of the technology on the stand will include the innovative machines for rolling and bending metal sheets and profiles from the Faccin Group, which will be presented by Qualimach. The Group through its three brands offers a portfolio of plate rolls, section rolls, dished headlines and special machines that serve industries worldwide.

Decade monitoring Systems will be demonstrating products and services for ensuring asset protection, consistent production quality, increased productivity and profitability. The Cloud enabled 180 series will be revealed at MACH along with its DLM, 160, 170 and MARS products. These products cover peak load protection, curve monitoring and downtime recording to complete  OEE Systems.

Formed in 1968, BRUDERER UK has established a reputation of excellence in high-speed precision stamping. At MACH, BRUDERER will be exhibiting a fully operational stamping production line, featuring the latest press technology, plus ancillary equipment from the portfolio. In addition, it will feature PressesServo feeders, de-coiling and re-wind equipment, tooling components, die handling solutions, OEE, press and tool monitoring protection systems, vision inspection systems, roller and spray lubrication equipment, product marking and multi-slide machines. 

Worcester Presses will be offering a combination of mechanical Chin Fong and Worcester bench press ranges, hydraulic presses, Tomac coil handling equipment and press transfer systems. It can offer turnkey solutions that incorporate guarding, load monitoring, QDC and additional ancillary equipment to increase productivity. Worcester Presses will also be exhibiting a Chin Fong OCP-110 tonne press.

Press-Form Machinery will showcase its new range of hydraulic, high speed press lines from VAPTECH. With laser projection and inspection solutions, Virtek will present its Laser QC for inspecting parts from pressed, punched and laser-cut operations. The ‘Laser QC’ inspects parts with accuracy and provides First Article Inspection reports. 

Industrial Clutch Parts (ICP) will display its range of Nexen linear and rotary roller pinion products for precision positioning requirements. ICP offer both versions of Nexen’s ring drive indexer systems based on roller pinion technology. Both the Compact Ring Drive and Precision Ring Drive enhance rotary positioning operations by providing positional accuracy, rigidity and acceleration.

Roemheld UK Ltd will be showing its new arch clamp that is sturdy and safe for use on presses and forges. With this clamp, ROEMHELD expands its multi-member wedge clamp family.

Unison to showcase tube bending

Unison will be presenting several new technologies at MACH on Stand 630 Hall 6. It will show an all-electric Unison Breeze 16mm (maximum tube diameter) multi-stack tube bending machine, equipped with the company’s Unibend control. There will also be a Unison EvBend 1000, a machine developed to reduce the entry cost to precision rotary draw tube bending by combining manually operated feed, tube rotation and bending force with CNC-controlled braking on the carriage feed, rotation and bend arm axes. 

Additionally, there will be the opportunity to get the lowdown on Unison’s newly launched range of Synergy HBM (hybrid, multi-stack) range of machines. Unison offers more than 30 all-electric tube and pipe bending machines for diameters ranging from 4 to 275mm with each model delivering rapid setup, fast tool changes, rigid mechanical design and an all-electric control for right-first-time repeat subcontract work. 

Available in 50 and 80mm versions, Unison’s new Synergy hybrid range combines electric and hydraulic operation. Just like Unison Breeze machines, each model benefits from a powerful and rigid mechanical design. As with Breeze models, bend arm, carriage, the plane of bend and carriage side shift are servo-driven, while mandrel, pressure die and clamping systems are hydraulically controlled.

Nukon brings precision laser cutting to MACH

Ingenium Integration Ltd, the sister company of UK-based tube bending machinery specialists Unison Ltd, will be showcasing the Nukon range of precision fibre laser cutting systems at MACH. 

Visitors to Stand 723 in Hall 6 will be able to see a Nukon Eco Speed Pro Line 315 4kW 2D fibre laser machine in action and discover why Ingenium Integration believes Nukon machines are ideal for first-time laser users.

“For quality machines, Nukon fibre lasers are incredibly accessible. Several models also have an extremely compact footprint, making them well-suited to production environments where floorspace is at a premium. Additionally, companies buying a Nukon fibre laser cutting system from Ingenium Integration can expect to receive the same level of service and support as enjoyed by users of Unison tube bending machines,” comments Ingenium Integration sales manager, Steve Haddrell. 

The Nukon fibre laser range includes 2D, 3D and laser tube cutting machines. Standard features include the nLIGHT fibre laser with adaptive beam optimisation and Lantek Expert software. Available in a range of power options and sheet sizes, the Nukon 2D fibre laser machines combine performance with efficiency. The Nukon range of 3D, 5-axis machines have been developed for challenging applications, such as precision-cutting tubes, pipes and intricate profiles in a wide variety of materials. The Nukon laser tube cutting machines also include pipe and profile cutting models, as well as the ‘Vento Flex’, a versatile machine to cut tubes, pipes, profiles and flat metal sheets. To assist customers in maximising the productivity and efficiency of their laser-cutting operations, Ingenium Integration also offers Nukon’s range of fully automated loading and unloading solutions for improved productivity.

Take your front row seat with Ficep UK

Get your popcorn at the ready, as Ficep UK is bringing the big screen to MACH 2022 to give visitors live demonstrations of its new and most popular machines. The steel processing equipment supplier’s stand in Hall 6 Stand 330 will feature a video wall with a live link-up to the Ficep HQ in Italy, where the team will showcase its new Kronos gantry style thermal cutting and drilling system and the Excalibur CNC horizontal single spindle drilling line. There will be a live link showing the Valiant CNC three spindle line and other machines from Ficep’s extensive range.

To support the live video link demos, the Ficep UK stand will feature the new Kronos machine for the first time to enable visitors to see the heavy-duty, gantry style thermal cutting and drilling system, which has been engineered for steel processors and fabricators for connection plates, gussets and stiffeners and other profiles from stock material.

The stand will also feature a tool vending machine that can reduce customers’ inventory costs and improve stock control. The vending machines give Ficep customers automated control over their tool stock by making tools and consumables readily accessible in-house. A swipe card system allows registered operators to select the tool or consumable they need, and the machine registers which part is taken, enabling invoicing to be done immediately.

All Rhodes lead to MMMA village

Designer and manufacturer of metal forming, composite and bespoke machinery Group Rhodes will be showcasing several innovations at MACH 2022 alongside group companies Rhodes Interform and Atkin Automation. The stand will feature as part of the MMMA Metalworking Village in Hall 6 Stand 616.

Rhodes Interform will be demonstrating its latest machine designs through Virtual Reality (VR), enabling visitors to experience the company’s new game engine architecture and take an interactive journey into the latest innovations in the company’s metal forming and composite portfolio.

Group Rhodes has recently introduced VR throughout its group companies, allowing customers to visualise project technology and assess practical aspects of the installation such as machine access, serviceability and equipment positioning. 

Mark Ridgway OBE, CEO of Group Rhodes, said: “MACH 2022 is a superb platform to demonstrate our extensive capabilities in the composite and metal forming industries.  Our experienced Rhodes Interform and Atkin Automation staff will be discussing how we can help manufacturers to meet their equipment requirements, using our expertise gained from almost 200 years in the metal forming industry.  We are also looking forward to highlighting through VR technology some of our latest innovations.”

Alongside Rhodes Interform, sister company Atkin Automation will be promoting its large portfolio of coil processing machinery, which includes a comprehensive range of Servo Roll Feeds. The current models accommodate material widths from 30mm up to 1.5m and thicknesses from 0.2 to 8mm. Grit blasted roll diameters of 60, 70, 100, 127  and 160mm cater for all applications. 

All Atkin feed units feature torque shaft upper roll pivots with a Regen grip system and backlash-free servo gearbox transmission. Controls are via a colour touchscreen control system with a facility to store relevant feed data including pitch length, speeds and cam angles against an alphanumeric part code. The system can be upgraded to include multi-pitching software with tool ‘gag’ control.

At MACH, Atkin will also be demonstrating the RF70-300 Servo Rollfeed (70mm diameter rolls by 300mm wide). It offers a manual height adjustable press mounting bracket, pneumatic pilot/strip release system and electronic cam-box.  Entry rolls and material side guides are standard with this machine, with options of motorised height adjustment and bespoke press or floor standing brackets. As well as equipment manufacture, Group Rhodes will also be highlighting its aftermarket service, delivered as the OEM for Rhodes, Atkin Automation, Fielding, Berry, Chester, John Shaw, HME, Bentley, Cowlishaw Walker, Kinghorn, Steco and other manufacturers’ equipment.

hyperMILL® end-to-end CAM is now more powerful

OPEN MIND Technologies will give its MACH exhibition premiere to the latest version of its hyperMILL^® CAD/CAM software. Version 2022.1 will incorporate more features, optimised strategies and a host of major enhancements for more powerful and simplified machine and controller independent NC programming.

On Stand 440 in Hall 17, OPEN MIND will demonstrate the optimisations to hyperMILL^® that include enhancements to the 5-axis strategies in VIRTUAL Machining. This will provide users with better results in terms of surface quality, new options for 2D functionality as well as efficient innovations in electrode manufacturing that deliver more convenient and faster programming.

hyperMILL^® VIRTUAL Machining is all about generating, optimising and simulating NC code reliably through a collection of targeted solutions. Virtual Machining can be used to map all process steps in CNC manufacturing for perfect process control. The modular technology now also supports additive machining programs. The Optimizer module, which delivers powerful optimisation algorithms for efficient multi-axis machining, also features the ‘Optimized Table-Table Logic’ function for easy programming and reduced air time between cuts. The user selects a distance value, and the Optimizer automatically calculates the safety distances using the raw part, component and clamps selected in the job list.

The defined distance is maintained for all components and the movement sequences are automatically optimised. This makes the generating of ideal linking movements even easier. Also, the new feature of direct data transmission in the CONNECTED Machining module provides additional safety during tool input. Instead of the traditional manual input, the parameters are transferred directly from hyperMILL^® to the controller.

Seamlessly merging the virtual and real world 

The three hyperMILL^® VIRTUAL Machining modules for the seamless merging of the virtual and real worlds form the core of the safe simulation solution. The Center module virtually maps real machining situations for the machine and controller and simulates these based on the NC code. The Optimizer module provides powerful optimisation algorithms that ensure efficient multi-axis machining. It also automatically identifies the best inclination for top machining results. The CONNECTED Machining module enables in-depth networking and synchronisation with the machine. 

Transforming the sheetmetal sector with Lantek

Sheet metal manufacturing software developer Lantek will be demonstrating how working with an industry specialist will provide the ability to automate and control your business by analysing machinery and customer KPIs by digitising the factory. Lantek will be in Hall 17 Stand 420 and the company will be presenting the Lantek Expert and Lantek Flex3d CAD/CAM solutions that give companies the ability to automatically create CNC programmess for virtually every sheetmetal machine on the market. 

Building on the technology and capabilities of this software, companies can start by adding Smart quotation modules to quickly and accurately generate quotations for customers. They can then move on to Lantek MES which keeps track of scheduling and machine OEE and then to Lantek’s cloud-based analytics software which will help them to understand the KPIs that are important to their company for both customer and manufacturing management.

Alberto López de Biñaspre, Managing Director of Lantek says: “We have traditionally invested large proportions of our income in research and development. Through our new partnership with TRUMPF, we now have the necessary resources to increasingly pursue this path. For 2022, we intend to make the largest investments in our company’s history. We want to increase our commitment to research and development by 70%. To do this, we plan to grow our workforce by 50% over the next twelve months from the current 260 employees worldwide, with a clear emphasis on R&D and our international customer support team.” 

As part of this initiative, Lantek will be growing its over 150 OEM partnerships to deliver an open system that can drive almost every sheet metal cutting machine on the market. MACH 2022 will give companies in the sheet metal sector an opportunity to find out how Lantek delivers the flexibility of being able to choose the best and most cost-effective machinery for their application and run it at its full potential.

CGTech takes productivity to the next level

‘If you always do what you’ve always done, you’ll get what you’ve always had’ is a truism that CGTech, the CNC simulation developer of VERICUT has been stating to manufacturers since the 1980s.

Visitors to the MACH stand 218 in Hall 19 will find out from the leader in NC code simulation how the software can take their business to the next level. With VERICUT, CGTech offers a wide range of products and solutions that ensure CNC machine tools run collision-free and manufacturing processes operate more efficiently with increased profit levels.

Demonstrations of the latest features in version 9.2, plus an exclusive preview of what’s to come in 9.3 of VERICUT CNC machine simulation and optimisation software will be conducted on the stand by the company’s technical engineers. VERICUT software is an industry-standard for simulating CNC machines to detect errors, potential collisions or areas of inefficiency. It operates independently, but can also be integrated with leading CAM systems.

CGTech will also demonstrate VERICUT’s Force optimisation module at MACH. VERICUT+ Force provides an integrated simulation-optimisation solution that can reduce machining times, improve cutting tool and machine life. New and legacy NC programs can be optimised with Force to run as efficiently and safely as possible. Force is available for milling, turning and mill-turn machines.

Force is a physics-and mathematics-based module designed to optimise feed rates of machine tools. The software uses actual data for cutting tool forces and spindle power readings to calculate maximum chip thickness and feed rate.

Sales Manager, Scott Ravenscroft, explains: “VERICUT covers the visible production elements, such as crashes, scrap, gouges and prove-outs. Force addresses the hidden opportunities. These include inefficient programming and suboptimal feed rates caused by the CAM system’s inability to adjust cutting feed rates for varying cutting conditions.”

Force relies on proven technology to maximise program efficiency and productivity and typically achieves savings of 8 to 15% on aluminium and 15%+ on difficult to cut materials. Return on investment can often be as little as one production component, with the opportunity to analyse cutting conditions, improve tool life, protect CNC machine tools and reduce operational costs.

Gavin Powell adds: “Companies now more than ever are realising the importance of simulation and the digital twin model. We are working closely with our customers and partners around the world to understand their exact needs. We deliver technical and economical solutions through the use of advanced technologies.”

Carfulan Group measures up

On Stand 460 in Hall 20, the Carfulan Group will be demonstrating its portfolio of products with metrology, additive manufacturing, tool pre-setting and turned part measurement technology on show from OGP UK, SYS Systems, ZOLLER UK and VICIVISION UK.

OGP UK will present its SmartScope Vantage 450 machine, designed to combine a variety of sensors for full 3D measurement. This system delivers optical performance alongside the highest standards of accuracy, repeatability and speed. Appearing alongside it will be the Smartscope CNC 200, CNC 500 and SP332. The CNC 200 and CNC 500 generate multi-sensor measurements, maintaining accuracy whilst withstanding the most hostile of environments. Generation of automatic component measurements alongside multi-sensor deployment mechanisms allow for unmanned inspection and high component throughput. 

SYS Systems will be showcasing a selection of Stratasys 3D printing machines. Suitable for a variety of applications, the F900, Fortus 450 and F370 systems will all be on show, as well as the J35 Pro PolyJet 3D printer which is revolutionising desktop prototyping. The F900 machine can print 16 materials from engineering-grade thermoplastics to high-performance polymers and is suited for early prototyping, functional prototyping, end-use parts, production tooling and more. The soluble support materials can produce complex geometries in one print without assembly. The high-strength material capability of Stratasys FDM technology is the standard in carbon fibre printing for tools and end-use parts that demand high strength and stiffness. 

For machine shops to tool manufacturers, the ZOLLER UK setting, measuring and tool pre-setting machines will be on show. The SmileCompact, Smile Pilot 1, Pilot 4 and Redomatic will preset and measure cutting tools offline with speed. Designed to work quickly and ergonomically in the manufacturing environment, the Smile range assesses tool length, diameter, radius, angle, concentricity and axial run-out in just seconds using pilotStarter image processing and touch-screen technology, as well as showcasing zidCode data transfer technology.

VICIVISION UK will show the X360, the brand new Prima 306, Techno M614 and the M309. For measuring the smallest of details, the X series of optical measuring devices have been designed to measure micro-mechanical components and general micro-parts. The high-resolution machines detect the smallest of details, measuring everything from cylindricity, roundness, axial and radial run-out. 

To optimise performance in smart automated factories, VICIVISION UK will also demonstrate the Metrios 2D digital optical measuring machine. At the press of a button, this versatile system performs accurate and objective part-quality tests directly on the shop floor, driving increased productivity and reducing both scrap and costs. Using automatic position detection with 100x magnification power and capable of inspecting multiple parts at the same time, complex measurements such as distances, angles, radii, diameters and roundness can be taken in seconds, all with a simple and intuitive click.

The latest in inspection from T3DMC

3D engineering solutions provider T3DMC (The 3D Measurement Company Ltd) will launch three new 3D scanning solutions at MACH. Visitors to Hall 19 Stand 639 will be able to see live demonstrations of the all-new SIMSCAN, KSCAN Magic and TrackScan P42.

The new SIMSCAN weighs only 570g and measures only 203 by 80 by 44mm. The SIMSCAN can capture areas of 410 by 400mm at a rate of over 2,000,000 measurements per second. The SIMSCAN is manufactured using aerospace-grade aluminium which makes this 3D scanner very robust, whilst also being very comfortable to hold and easy to use. 

Building on the success of the previous KSCAN series, the KSCAN Magic scanner is packed with 41 blue laser lines and delivers scanning speeds of up to 1.6 million measurements per second. The KSCAN Magic has five separate measurement modes in one scanner and this includes built-in photogrammetry.

The TrackScan P42 will also be on show to demonstrate how to capture accurate and highly detailed data without the use of reference markers. The P42 3D scanning system boasts 1.9 million measurements per second. This combined with a large measurement volume of up to 16.5m³ and dual measurement volumes for small and large parts makes the P42 an extremely versatile and capable measurement system.

Measurement for any environment

Aberlink will exhibit several new metrology products at MACH with the new second-generation Extol shop-floor CMM and the Horizon CMM. On Stand 507 in Hall 19, the Extol will be on show and it is available in two sizes. It also supports touch-probe and contact scanning. 

The Aberlink CMM can error map the forty-two degrees of freedom found within a non-cartesian delta mechanism and considering the measuring range offered by the two different sized Extol CMMs, their overall footprint is very compact. The Extol CMM can be installed exactly where it is needed on the shop floor. 

Aberlink will also show the new linear drive Horizon CMM. It is manufactured with frictionless linear drives and the isolated kinematic drive structure is completely independent of the CMM structure to ensure the motor thrust is directed through the centre of gravity of the moving parts. This avoids acceleration induced metrology errors and thermally isolates the linear motors from the metrology structure of the CMM. A non-homogenous X-beam optimises the stiffness-to-weight ratio along the entire axis. 

Aberlink will also exhibit a new manual measuring machine. The new Fulcrum machine uses a three rotary axis design to enable fast and accurate 3D inspection of parts. This desktop measuring machine enables high accuracy easy to use manual inspection next to the machine tools where the parts are produced. The software interface has been streamlined to make it easy for people with no previous CMM experience to quickly and intuitively start measuring parts with the minimum of training.

New workholding products for automated production

In Hall 6 on Stand 450, Roemheld will give a UK debut to a new, modular, sensor-based system that digitalises zero-point clamping by enabling digital recording of its status. STARK.intelligence enables data on workpiece loading and unloading to be integrated directly into an automated manufacturing process. Information is also provided on the condition of the clamping equipment to facilitate its scheduled maintenance.

Each fixture is equipped with its sensor box to measure position, temperature and pressure in real-time. A master unit receives data from several units and outputs the information to different devices via an IO-Link. STARK.intelligence can be combined with various STARK zero-point clamping systems and may be retrofitted easily to machine tables and quick-release fixture plates. Due to the modular design, users can choose between individual components or a complete solution, which may include the integration of an RFID interface that automatically detects pallets and workpieces. 

Another introduction at the show will be a range of compact bore clamps with a large clamping range for five-sided machining. The devices hold internally, exerting force both radially outwards and downwards against a support surface. The new models enable safe location in bores from 5.2mm to 13.7mm, so are suitable for clamping small workpieces. The support height is also easily adjustable to suit workpieces having clamping surfaces at different levels. An air blast helps to keep the bushing clean and ensures reliable operation. 

A third innovation will be a compact flat lever clamp designed for use on fixtures in machine tools with low-pressure hydraulics between 70 and 120 bar. It complements the successful Roemheld series rated at up to 250 bar. The hydraulic, double-acting element is suitable for mounting in any position. There are built-in and block-type varieties as well as versions without a housing for installation in restricted spaces. 

Due to the flat clamping levers, even surfaces only a few millimetres above the clamping level can be machined without any problems. Depending on the operating pressure and lever length, clamping forces of up to 33kN are possible. 

Roemheld will also show two models from its large range of machine vices. Most flexible is the Hilma VarioLine, which is used vertically or horizontally and may be quickly adapted to different workpiece sizes due to magnetically-secured, quick-change jaws that can be exchanged in a single action. They can be individually configured using various parameters to adapt them to different machines and applications. The other vice will be the Hilma MC-P, intended for securing parts during 5-axis machining.

ANCA to show application capacity

ANCA UK will show a CPX blank preparation machine and the MX7 Linear tool grinder at MACH on Stand 132 in Hall 20. ANCA will feature the latest in-process measurement functions for the production of PCD tools, gear making and automated production lines will also be presented. As well as the machines on display, ANCA will introduce the new spark generator on the EDG series hybrid machines for grinding and erosion, the GCX platform for hobs and skiving tools with design software and integrated measuring; and the autonomous manufacturing solution AIMS (ANCA integrated manufacturing system), a modular set of hardware and software products and components allowing for the integration of the entire process chain and production process. 

Advanced Grinding Solutions at MACH

Every machine on the Advanced Grinding Solutions (AGS) stand at MACH will be receiving UK debuts on their Stand 320 in Hall 17. AGS is showing the new Rollomatic 660XW GrindSmart multi-axis tool grinding machine along with Tschudin, Comat and FLP machines.

The latest Rollomatic machine combines the performance of a blank prep cylindrical grinder with the flexibility of a multi-axis tool grinder. The latest technology brings gains in production efficiency for tool manufacturers and the savings are made because lengthy setups on multiple machines are avoided. Typical production efficiency from the traditional multi-machine production method for standard end mills is in the region of 11% and this is increased to some 82% on the Rollomatic 660XW machine. 

Also on display for the first time is the latest Tschudin Cube centreless grinding machine. The Tschudin Cube machine benefits from a new design that enables users to achieve productivity gains. The grinder can be manually loaded outside of the grinding zone and it uses Tschudins patented W-axis that has the workrest blade mounted onto its CNC axis that makes loading efficient, fast, and very safe. 

Another UK debutant will be the Comat C-120 filtration system. Comat superfiltration systems are engineered to filter neat cutting oil to 2 to 3 microns whilst constantly maintaining a stable temperature (+/-0.2 degrees), without compromising filtration or flow rates.  Comat superfiltration systems minimise running costs to obtain the lowest cost per litre of oil filtered. The C120 is the latest compact superfiltration system designed to manage a single machine tool and can filter any contaminant to guarantee intelligent performance with process optimisation by remote monitoring.

FLP (Fine Grinding, Lapping and Polishing Machines) are showing their new FLP380 single-sided lapping machine. The range of FLP machines also includes twin wheel – double-sided CNC lapping and fine grinding machines. 

FLP Double Disc or twin wheel machines have seven machines in the range offering a working disc diameter of between 540mm and 1.3m. These can be offered with full automation via linear or robotic solutions, and weigh between 7 and 16 tonnes. These machines are offered as high-precision versions with granite machine beds and the latest machine controls. 

Specialists from Krebs & Riedel will be present on the AGS stand to discuss all grinding applications and the best use of their range of internal and external grinding wheels. Krebs & Riedel manufacture high quality conventional, diamond and CBN abrasives and are constantly introducing new types of wheels with improved grain structures and novel bonding systems that enhance grinding wheel quality and optimise performance.

Complete tooling solutions from ITC

UK cutting tool manufacturer, Industrial Tooling Corporation (ITC) will once again be demonstrating the ‘Best of British’ at MACH. The Tamworth based cutting tool company will be introducing a host of new solid carbide and PCD tooling innovations as well as the latest new product lines from WIDIA, BIG KAISER, Kemmler and Bass.  

To complement the ITC range of cutting tools at MACH, Stand 555 in Hall 20 will present the innovations from BIG KAISER. This will include a MACH debut for the EWN Smart Damper precision boring heads. 

For manufacturers involved in boring operations, ITC has expanded the BIG KAISER offering of precision boring heads. Now, ITC has released two smaller sizes of the EWN Smart Damper precision boring heads – the CK1 and CK2. The new heads eliminate vibration in deep-hole finish boring with a patented damping system. 

The additions make it the first time the EWN Smart Damper has been available in diameters below 32mm, taking it down to 19.99mm. The CK1 head has a length of 100mm and the CK2 125mm. BIG KAISER’s modular CK/CKB system allows for versatility in the length of tooling combinations, giving 10XD boring that can run on nearly every major spindle interface.

All tools have through coolant facility and have three different insert holder options per head size. The EWN analogue head features a dial with Ø0.012mm/div setting accuracy with vernier adjustment down to 0.0025mm. The integral design of the new Smart Damper heads shortens the distance from the damping mechanism to the cutting edge, which can be a source of vibration. By shortening this distance, the EWN produces improved damping effects on the tool assembly and this minimises chatter and vibration.

Alongside the precision boring heads, ITC will introduce the BIG KAISER hydraulic chucks for Swiss-type turning centres. BIG KAISER has expanded the program to include inch-size standard type chucks, as well as the new F-Type and R-Type chucks. The new F-Type single wrench system simplifies cutting tool changes on the tool post, saving setting time for the machine operator. The easy-access rear clamping design is ideal for configurations where the hydraulic chucks are installed on the front tool post of a sliding head turning centre. Clamping from the opposite side of the cutting tool and the optimised overall length design improves ease of use. The F-Type is available in a clamping range from 3 to 10mm. Alongside the new F-Type single wrench system is the new R-Type designation. This design eliminates interference when working on both the upper and lower tool post. 

Also on show will be the Mega Synchro Tapping Chuck. The new tapping chuck has a special function built-in to compensate for synchronisation errors that may occur during rigid tapping.  

Another product destined to improve set-ups, precision and productivity is the Base Master high-precision compact touch sensor that rapidly determines workpiece offsets and tool lengths. The Base Master has a compact design that makes it very fast and easy to use while providing extremely accurate results. For rapid reference point detection, it is fitted with a bright red LED that illuminates at exactly 50mm from the reference surface. This allows the operator to quickly touch off a tool with zero risk of damage or breakage, thereby saving precious time and money. The Base Master has a very tight repeatability of only ±0.001mm and for maximum flexibility, it has a solid magnetic base that mounts vertically, horizontally, or at any angle. 

Minimal set-up and changeover times for turning

Heimatec will introduce its heimatec.Capto™ at MACH in Hall 20 Stand 243. Heimatec is expanding its product range with a further modular tool quick-change system, which increases efficiency and tool changeover times. The heimatec.Capto™ offers wide modularity as well as a variety of change-over inserts for lathes and machining centres. 

In addition to a wide range of standard tools with Capto adaptions, the heimatec.Capto™ program also offers a large number of specific tools designed for machine optimisation. The modular quick-change system is characterised by a compact design with a short overall length that allows high cutting speeds and surface quality. The heimatec.Capto™ tool quick-change system is available for Capto sizes C3, C4, C5, C6 and C8.

The company will also show its heimatec.SwissTooling that offers a comprehensive range of static and driven tooling units for many types of Swiss-type lathes. Machining companies can implement heimatec radial drilling and milling heads, woodruff key cutters, multi-spindle adapters, multi-spindle heads and radial drilling heads with maximum speeds of 6,000 to 10,000rpm. In addition, 2, 3 or even 4-spindle radial drilling heads are available as double-spindles.

Floyd to bring new technology to MACH

Floyd Automatic Tooling will have sliding head machines on its stand at MACH 2022 from the world’s leading manufacturers. On Stand 472 in Hall 20, the sliding head machines will be tooled-up with the latest innovations from the Baldock cutting tool specialists, demonstrating the extensive portfolio available.

Floyd Automatic will showcase the ever-expanding range of innovations that now include the Swiss cutting tool brand Denitool and also the German JBO brand. Both JBO and Denitool will be making a MACH exhibition premiere and the addition of JBO to the Floyd stable will give the company an impressive range of thread milling cutters, shell type thread milling tools, threading dies, combination tools and precision thread gauges.  

Additionally, with Floyd Automatic recently announced as the new UK sales and distribution partner of Denitool, the Hertfordshire company has also incorporated a high-performance range of fine boring tools into its portfolio. The Denitool range of boring tools is a line of solid carbide boring bars with a multitude of indexable insert geometries and grades to improve the performance of small part turning operations. This new range of turning and boring tools will strengthen the offering whilst providing turned parts manufacturers with a new range of tools that complement the already extensive and high-quality product lines available.

Also on show will be the new Hydro-Swiss Turn range of compact hydraulic clamping tool holders for cylindrical tools. Capable of maintaining precision and run-out levels of less than 1 micron, ‘ultra-precise’ is now possible for your sliding head CNC turning centres. Regardless of the turning centre, the new Hydro-Swiss Turn holders are compatible with all leading sliding head machine brands. The Hydro-Swiss Turn holders are available as a standard or as an ultra-precise (UP) variant that can achieve a run-out of 0.003mm and 0.001TIR respectively. 

Another MACH debutant will be the new Precitronics TOHP Series of driven tooling with integrated high-pressure coolant feed. The TOHP system offers high-pressure through coolant delivery up to 135 bar for driven tools and applications on sliding head turning centres. With the recent pandemic forcing more businesses to look at their costs, Floyd Automatic will also showcase the new cost-effective MicroTurn eLine of boring tools from Ifanger. The new MicroTurn eLine MTEE is an optimised universal boring tool that is less expensive than Ifanger’s existing MTEC or MTEN tools and significantly more cost-effective than solutions from alternate vendors.

Rainford ‘FREE’ tool giveaway

The Rainford Precision stand at MACH will provide a FREE cutting tool giveaway as well as introducing two new brands to the UK. Rainford has been announced as the new distribution partners for both 6C Tools AG and BSQ Tech GmbH, the innovations will be presented for the first time on Stand 573 in Hall 20. 

The tools from 6C Tools AG are manufactured by laser ablation for a sharper edge finish. The 6C range covers several drilling, milling and threading tools as well as tailored tools manufactured from PCD and PCBN. Designed for materials such as ceramics, tungsten carbide, zirconium, sapphire, glass and glass ceramics, the 6C portfolio introduces PCD drills, end mills, chamfer tools, ball nose mills and ball nosed polish tools and thread mills.  

The 6C range is ideal for the optical, medical, electronics, jewellery and semi-conductor industries. The 6C tools are produced for the machining of small components and features. For example, the through coolant PCD drilling tools are available in 0.1mm increments from 0.3mm diameter to 3mm with 2XD and 3XD, 4XD and 5XD drills are also offered. 

Completing the 6C Tools at MACH will be the micro thread mills available from 0.9 to 1.7mm for the threading of small holes in abrasive materials. 

For engineers looking to improve productivity when machining aluminium, aluminium alloys, copper brass, plastics, PEEK and all other non-ferrous metals, Rainford will introduce the SwissCeraMill series from BSQ Tech GmbH that can increase tool life up to 25 times and improve productivity by 400% compared to conventional carbide cutting tools. 

Manufactured from ceramic zirconium oxide, the SwissCeraMill end mills are available with a square end, corner radius and ball nose designations as well as Torus and special-purpose tools. The square-end tools are available from 1 to 20mm and with the chamfer tools, the 45-degree chamfer on the smallest tools starts at 0.05mm ranging up to 0.5mm on the 20mm diameter tools whilst corner radius tools start from 0.5 to 2mm. For profiling applications, the ball nosed series is available from 4 to 20mm diameter. As well as the Union Tool V-Series giveaway of 300 tools at MACH, the 6C Tools AG and BSQ Tech GmbH SwissCeraMill, Rainford Precision will also be demonstrating cutting tools from Louis Bélet, HOBE, DTS, Delmeco, Gloor, Osawa, Iwata and ATOM.

New reaming and thread milling tools

A new, modular system for reaming large diameter holes will be on show for the first time at MACH on the Horn Stand 340 in Hall 20. The DR-large reamers have exchangeable heads with multiple solid carbide inserts, resulting in high cutting values, short cycle times and low costs. The insert seat has been designed for micron precision changeovers and tool setting is unnecessary when exchanging the head.

The system is suitable for bore diameters from 140 to 200.2mm. Six cutter heads cover the range of diameters in 10mm increments, with two sizes fitting on each size reamer shank. Modular construction and an ABS-compatible interface mean the tool can be extended to any length.

Also new at MACH will be Horn’s products for circular interpolation milling of holes down to 8mm diameter. The triple-edged 304 system offers a versatile, productive solution for internal groove, thread and profile milling. The insert has a cutting diameter of 7.7mm.

The inserts are available in widths of 0.5, 1, 1.5 and 2mm. For milling circlip grooves, Horn offers the system with cutting widths of 0.8, 0.9, 1.1 and 1.3mm. To enable the milling of chamfers, angles of 45, 30 and 15 degrees are available. Regarding substrates, Horn uses coated grade EG55 for general steel machining and IG35 for superalloys.

Horn will also explain the importance of two new high-performance coatings, the IG6 and SG3. Despite being less than 0.005mm thick, such coatings can extend service life by a factor of 10 or more. IG6 is a copper-coloured AlTiSiN coating for steels in groups P and M with Horn’s S224 and S229 grooving systems. In conjunction with an adapted carbide substrate, the coating allows faster material removal rates. Horn’s SG3 coating is designed for machining titanium alloys and superalloys as well as hard turning and grooving.

Also making a debut will be Horn’s expanded DS range of solid carbide end mills with a new geometry for HPC milling of high strength steels. It excels in dynamic roughing  as well as in standard roughing cycles. Different helix angles create an irregular tooth pitch, making the operation smooth. The end mills are available in diameters from 2 to 16mm with four or five flutes.

The optimised face geometry reduces the cutting pressure during linear or circular ramping. Improved chip spaces ensure optimal process reliability during chip formation and removal. Smooth operation means that high surface quality can be achieved during side milling. HPC milling of high strength steels at fast metal removal rates places significant demands on the tools and the new carbide substrates and tool coating make this process feasible. Horn relies on the ES3P grade, again with a HiPIMS coating. 

Morgan Revs-Up Oemeta Stand

With a stunning heritage 3-wheeler car taking centre-stage, courtesy of prestigious customer, Morgan, the team from Oemeta UK is looking forward to MACH. At the show, visitors can learn about how the relationship between the companies started and how quality and coolant support in the Malvern-based machine shop improved with the onboarding of Oemeta UK.

Also being featured by Oemeta UK on Stand 363 in Hall 19 are 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 multifunctional 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 coolant and combines high-performance with cost-efficiency. It is ideal on hard-to-machine materials such as high-alloyed steel, and aluminium and titanium alloys.

VOLLMER to premiere new grinding technology

Following its world premiere at EMO, VOLLMER will give its UK debut to the new VGrind 360S grinding machine. For the complete machining of carbide tools, the Vgrind 360S on Stand 550 in Hall 20 will appear alongside the CHX/HS and the VOLLMER Loroch Powerstar machines for sharpening circular saw blades. 

The impressive new VGrind 360S can be used to machine carbide tools with a diameter up to 25.4mm and depending on the machine kinematics and the equipping of the grinding wheel packages, it can even be used for tools up to 150mm diameter. 

With more precision and power thanks to its linear induction motor and linear slides, the VGrind 360S reduces maintenance costs by utilising magnets. Furthermore, the kinematics deliver improved precision and higher surface quality on the cutting tool. 

For simple and intuitive operation, VOLLMER has created an ergonomic platform whereby users can operate the control panel comfortably whilst having full visibility of the work envelope. Operation via the keyboard or touchscreen allows for precise machining of the tool and the multi-function handwheel ensures even more flexibility as it can be freely positioned on the enclosure. 

The vertical double-spindle concept, now features an oriented spindle-stop for the first time. Known as spindle indexing, this always stops the spindle at a specific position and the result is a reduction of axial run-out errors and concentricity issues whilst offsetting wear in the HSK holding system. Another new feature is a heat plate exchanger to efficiently cool motors and spindles, which in turn leads to increased thermal stability. 

The VGrind 360S incorporates VOLLMER’s operating concept and can be operated unmanned around the clock thanks to automation features such as a pallet magazine, free-arm robot or chain magazine. 

10 times and counting at MACH

The MACH exhibition will mark the 10th consecutive occasion that Close Brothers Asset Finance will have participated in the event. To mark the occasion, MTD magazine spoke to Steve Gee, the CEO of Close Brothers Industrial Equipment Division. 

Steve told MTD: “We were ever-present during the financial crisis from 2008 to 2012 when no other funders exhibited. There were many deals struck at the show, and a notable one was the first machine we funded for BCW for £95k. At the time, the company was a new business. Today, the company is 20 years old and an extremely successful multi-national with a turnover in excess of £30m, for who we have funded around £10m in all, over the years.” 

“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.”

Close Brothers SME Apprenticeship Scheme 

In April 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. The scheme is supported by the AMRC Training Centre in Rotherham and the MTA. It is targeted at SMEs who might otherwise not be able to afford to take on an apprentice. 

Each year, Close Brothers pays for 20 apprentices, contributing 50% of the 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 need assistance to take on apprentices, so we designed our programme to help. We believe the scheme has made a real difference to the business results of participating SMEs. As we move forward, we look forward to continuing this important initiative in partnership with the AMRC,” added Steve. 

Major turning centre launch

A new range of four driven-tool CNC turning centres will be launched by Hurco at MACH. The models include 8-inch and 10-inch chuck versions with the option of a programmable W-axis to position the tailstock or sub-spindle. One model, the TMX8MYSi, will be on show for the first time in the UK and will be centre-stage on the company’s stand 510 in Hall 20. 

The new TMX turning centres offer higher performance than the TMi and TMMi. The differences are higher power and speed plus a larger, heavier frame and the addition of a Y-axis in addition to the W-axis to allow more versatile machining. The servo-driven turret carries 12 VDI 40 radial tools, rather than axial tools, as on the TMMi range.

Two additional Hurco CNC lathes will be on show, the TM6i XP and the TM8Mi XP with axially driven tools. The suffix denotes the 2020 upgrade of the previous models, including larger spindle bore, roller guideways and an improved control system.

On show for the first time at a MACH will be the BX60i 3-axis, double-column, portal machining centre that maintains dynamic stability and accuracy despite having large X and Y-axis travel. Ideal for producing large components, the BX60i has a working volume more than twice as large as that of its smaller counterpart. Positional accuracy is maintained via linear scales. 

In addition to the VM10i, there will be a VMX30Di with a direct-drive 15,000rpm spindle, while a large VMX60Ti with a high-torque 237Nm spindle will complete the line-up. 

The Max5 control will be evident on all Hurco machines. Visitors will have the opportunity to see the latest software developments, including solid model import that now includes surfaces. 

One Hurco 5-axis machining centre on show will be the VMX42SRTi, the latest version has directly-encoded torque motors driving both the B-axis spindle and C-axis rotary table. Linear scales and 20 bar coolant through the spindle are now standard features on the SRTi as well as on the 4-axis SWi swivel-head models. 

In addition to a smaller Hurco VMX42SRTi B-axis machine, the compact VMX30UDi 5-axis trunnion-type, direct-drive, 15,000rpm model with 200kg load capacity will be demonstrated. A compact, entry-level, 5-axis VM10Ui and a VMX60Ti 3-axis machine equipped with a Kitagawa TT182 rotary-tilt table will also feature. 

There will be a total of five machines with 5-axis capability cutting metal, including a RXP500DSC. Built by Roeders in Germany, the machining centre is of trunnion configuration and is capable of super-high accuracy and of producing a mirror-like surface finish. 

The addition of automation is well established and relatively simple. On the stand at MACH, there will be a Hurco ProCobot Profeeder assisting the production of parts on a VM20i 3-axis machining centre and an Erowa Robot Compact 80 feeding the new VMX30UDi VMC.

A great Mate for workholding and fabrication

Mate Tooling Solutions is the authorised UK dealer for US-based Mate Precision Technologies products and on Stand 272 in Hall 20 at MACH, Mate’s next-generation 52/96 workholding system for CNC machining operations and the patent-pending QCT™ quick-change, tool-less thick turret punching system will be on show.

The new line of 52/96 vices, bases and mounting systems maximises holding power in a compact, quick-change modular design that reduces setup time and process variability for 3, 4 and 5-axis machining centres. Mate leveraged seven decades of machining experience to create a new level of innovative workholding with an impressive selection of options. This includes the Mate DynoGrip™ self-centring vices with maximum holding power in a compact system with minimal part movement and zero-point quality engagement with a four-post pull stud pattern, the Mate DynoLock™ quick-change bases with a four-post stud pattern and best-in-class centre accuracy and also the Mate DynoMount™ system that includes tombstones, pyramids, risers and dual right-angle mounts that feature zero-point quality engagement for four-point stud patterns.

The Mate 52/96 workholding system includes QuickSpecs™, Mate’s unique product identification system that allows real-time access to critical user data, CAD models and potential integration into business systems. 

Mate Precision Technologies’ QCT™ thick turret tooling will also be on show to take insert-style punching systems to a whole new level. The tool-less punch retention mechanism makes changing the punch insert a breeze. QCT’s durable patent-pending design is designed to minimise effort and maximise uptime.

QCT punch inserts are made from M4PM™ steel, the longest-lasting tool steel in the industry. Only one punch driver is required for rounds or shapes. All punch drivers come standard with Mate’s Supermax™ coating for extended life. QCT is available in both A and B stations in the following styles – the Ultra® QCT™ works with all existing Mate UltraTEC guides and canisters, Mate Ultra XT guides and canisters; the Metric QCT™ A and B Station punch drivers that are also available with Mate Ultra® family of guides and standard canisters plus the AMX QCT™. The AMX QCT™ is fully compatible with Mate AMX™ guides, spring packs and Rapidset canisters, as well as Amada NCT, NEX and Z-Tooling air blow systems.

New-generation HMCs from Heller

Heller Machine Tools will show its second-generation HF 3500 5-axis horizontal machining centre (HMC) model at MACH. The company will also feature the fourth generation of its H-Series 4-axis HMCs on Stand 130 in Hall 20.

The HF 3500 Gen2 and the larger HF 5500 are available with a fixed table or an automatic pallet changer. Both are built-in Redditch and incorporate improvements over the previous generation. Both machines are offered with either an HSK-A63 or HSK-A100 tool interface in three versions, POWER, SPEED and the new option of PRO, the latter intended for long periods of simultaneous 5-axis machining. 

Designed to raise cutting performance, innovations include halving the minimum distance between the spindle nose and the centreline of the 225-degree swivelling trunnion; the availability of twin motors and ballscrew drives and the offer of six new spindles. Other notable improvements include increased stiffness of key components, shorter chip-to-chip times and faster tool change from a chain-type magazine with up to 240 pockets or a rack-type magazine with up to 405 positions. The high-end PRO package additionally offers 10m/s2 acceleration in X, Y and Z. 

On the HF 3500 there is the new availability of a pair of DC (dynamic cutting) universal direct-drive motor spindles, HSK-A63/16,000rpm 56kW and HSK-A100/12,000rpm 45kW. To minimise non-productive times, Heller has succeeded in achieving a big reduction in run-up times for the new spindles, maximum revs are now reached in 1.4 seconds for the HSK-A63 variants, 1.8 seconds for HSK-A100. All spindles feature Heller’s Zero-Spindle system for rapid interchangeability, leading to maximum machine availability coupled with low service costs.

Featured at MACH 2022 will be Heller4Industry, the group’s worldwide drive towards integration of its machine tools and controls into the Industry 4.0 environment. Within the multi-faceted portfolio is HELLER4Operation, an easy-to-use, operator-oriented user interface. 

The HELLER4Services interface focuses on transparency of digital manufacturing and maintenance and the HELLER4Performance includes workpiece-specific analysis for optimisation of a process and extraction of real-time data over the internet, plus evaluation and graphical display in the cloud.

16 machines from Mills

A total of 16 machine tools, including seven new models, two advanced ‘SYNERGi’ automated manufacturing cells and three cobots and software will be shown by Mills on Stand 100 in Hall 19.

Mills is showcasing 16 machines with seven new models that have just been introduced. The seven new models comprise two turning centres, two mill/turn machines and three machining centres.

The two new turning centres are the Lynx 2600SY turning centre equipped with a Y-axis and sub-spindle which is integrated with an advanced SYNERGi Premier automation system and the multi-tasking TT 1300SYYB – a twin-spindle/twin-turret turning centre with Y-axis capabilities on both its upper and lower turrets.

Mills will also show the SMX 2100ST and SMX 5100LB. The 8-inch chuck SMX 2100ST is a multi-tasking machine with a 1040mm maximum turning length, a B-axis milling spindle, a Y-axis and a 12-station lower turret. The large-capacity 21 inch chuck SMX 5100LB has a maximum turning length and diameter of 3050mm and 830mm respectively plus a 120-tool position ATC.

The three new machining centres comprise the new SVM 4100, the BVM 5700 and the T-4000HS. The SVM 4100 is a VMC designed for machining aluminium alloys. The machine boasts fast acceleration/deceleration rates and fast tool change times. The BVM 5700 is a machining centre that delivers greater flexibility and performance.

The T-4000HS is a machining centre with 48m/min rapids, an 11kW/24,000rpm spindle and a 21-tool position ATC. The machine is ideal for rigid tapping and drilling operations and, at MACH it will be integrated with a SYNERGi Sprint system to create an automated cell.

The other nine machines on Mills’ stand include models from the company’s best-selling ranges such as the DNM (4500, 5700, 6700) vertical machining centre series.

Lathes from its Puma range include the large-capacity Puma 5100LMB lathe and the Puma 2600SY II. The DVF 5000 is being showcased with an integrated AWC (Automatic Workpiece Changer) that further increases the machine’s productivity.

There are three different cobot series (A, M and H) in the Doosan Robotics range and a total of five cobots are being showcased on Mills’ stand. Performing machine tool tending tasks and integrated with vision systems to realise inspection potential – all cobots will demonstrate their ease-of-use and ease of deployment.

Kerf to unveil new cutting technologies

In Hall 17 on Stand 309, Kerf Developments will present a mix of cost-efficient high technology cutting solutions. At MACH, Kerf will expect its RUR2500P high definition plasma cutting machine to create a spark of attraction. 

With its UltraSharp cutting technology, the machine is suitable for subcontract profilers, fabricators, structural steel, construction, rail and heavy engineering professionals. It combines both speed and precision with the consistently high cut quality and the lowest possible cost of manufacture. The RUR incorporates a rigid frame design that is ultrasonically stress relieved and this robust build quality and precision cutting has made the RUR2500P a popular choice for heavy industry sectors. The RUR2500P has a cut width of 2m and the modular design permits table dimensions to be tailored to the demands of the user.

Alongside the RUR2500P, will be the new Fineline 300 Plasma unit from Lincoln Electric that incorporates Advanced Piercing Technology and a new Watermist system. The Fineline 300HD delivers exceptional cut quality when cutting. Designed to allow full user control from a single interface, customers can change plasma current and gas pressures for better cut quality. With a small 38mm diameter 300A torch, the FineLine 300HD minimises secondary processing with its new Magnum PRO LC300M torch. Working with the UltraSharp 2.0, plasma current controls are all synchronised to control motion, gas flow, cut speeds and height control. 

The FineLine 300HD also includes Advanced Process Control, an advanced piercing system that provides highly repeatable hole cutting. The FineLine 300HD also introduces a new water injection system that improves performance on stainless and aluminium. The watermist system improves the cut quality on aluminium by using water as the secondary gas to control the atmosphere in the cutting zone. The result is repeatable perpendicular edges, clean and precisely finished cuts, dross, smoke, and dust reduction as well as significantly reduced running costs. By reducing the heat zone, the water system improves the definition of corners, reduces bevels, and delivers a lower cost per cutting metre.  

Also making its debut, the new Optima 216 waterjet cutting machine features a 2 by 1.6m cutting table that will appeal to manufacturers with limited floor areas that require a solution to undertake everything from one-off and general jobbing work through to batch production. 

MACH first for new Victor machines

The GM Group will make its MACH debut appearance with machines that will ‘wow’ the crowds. On Stand 619 in Hall 19 visitors can witness exactly why the build quality and flexibility of the Victor range stands above its rivals. 

The GM Group will introduce the Victor Vturn-A20YCM and the Vturn-S26/60CM single-spindle turning centres and the Vcenter-P76 VMC. The machines on show will provide just a snapshot of what is possible.  

The turning portfolio has uncompromising levels of rigidity and stability that deliver class-leading precision, flexibility and productivity and the GM Group will highlight the benefits of the compact Vturn A20-YCM single-spindle turning centre with its Y-axis milling capability and an 8-inch chuck with a swing over bed of 700mm whilst a 52mm diameter bar can pass through the headstock for barfeeding applications. The machine provides X-axis travel of 150+35mm with 600mm in the Z-axis whilst the Y-axis driven tooling unit can traverse +/-45mm. Within this spacious work envelope sits a main spindle that generates 11/18.5kW power with a spindle speed of 5000rpm. With class-leading power output and a driven tooling unit that is all manufactured in-house by Victor, the Vturn is extremely well equipped with a list of options that include a FANUC 0i-TF CNC control unit, 10.4 inch colour display, high-pressure coolant system, part catcher, oil skimmer, programmable tailstock and much more.  

Complementing the Vturn A20-YCM will be the Victor Vturn-S26/60CM. With a 600mm swing over bed and 640mm between centres, the 6230kg powerhouse has a spacious work area and a compact footprint. Furthermore, with a 12 position live tooling station that can drive the 25mm maximum tool diameter at 6000rpm with its high torque 4.5kW motor, the milling flexibility of the Vturn-S26/60CM facilitates productive one-hit machining. Like the Vturn A20-YCM, the Victor Vturn-S26/60CM is available with an extensive list of optional extras that enable this machine to be tailored to the exact needs of the end-user. 

From its milling portfolio, the GM Group will introduce the Vcenter-P76 compact 3-axis VMC. Packing the power, rigidity and performance that Victor is renowned for, into a compact machining centre will be something to look out for. With a 2.8 by 2.7m footprint and an X, Y and Z-axis travel of 760 by 500 by 510mm, the Vcenter-P76 is remarkably spacious to facilitate the machining of small and large components alike. Incorporating a 15,000rpm 11/15kW spindle motor with the extremely rigid BBT40 spindle taper configuration, rigidity and performance is guaranteed. The machine is available with a 30 position ATC but like many features on the Vcenter-P76, a host of optional choices can be selected to meet the demands of the end-user. 

The machines on show at MACH will be just a snapshot of what is available from the GM Group. The extensive range of machine tools includes single and twin-spindle turning centres as well as 3 to 5-axis machining centres of all sizes and capabilities. If you want to see why more manufacturers are opting for the Victor brand from the GM Group, visit Stand 619 in Hall 19.

Grinding and turning to take centre stage for RK International

RK International Machine Tools will demonstrate its grinding portfolio and the recently introduced EUROPA eturn VS range of manual lathes at MACH in Hall 20 on Stand 265. In total, seven machines will be on display. Grinding machines from supply partners Robbi, Perfect, Delta, and Jainnher will be shown; covering all aspects of abrasive machining through universal and surface grinding, vertical spindle rotary table and centreless grinding. For manual turning, visitors will see the EUROPA eturn mid-range VS390 gap bed lathe.

There will be two machines on show from Robbi, the Robbi Omicron 1000R universal grinder and the Robbi Omicron T7 PLC universal grinder. The Omicron1000R is the smallest in the R-series with a distance between the centre of 1m. The Omicron T7 PLC features the latest control system with touch screen for ease of programming.

The Perfect range of grinders will be represented by the new PFG-3060DT range of touchscreen controlled surface grinders. The Perfect PFG-400R rotary table surface grinder is representing the company’s R series of horizontal spindle, rotary table models. Often referred to as a ring grinder, the spindle is a class P4 high precision angular contact bearing unit, giving run-out accuracy of 2μm. Representing the Delta range will be the LC500 vertical spindle, rotary table surface grinder. The LC500 can grind 500mm diameter up to 205mm high. Centreless grinding is represented by the Jainnher JHC12S machine. It allows through-feed and plunge grinding of components measuring up to 40mm diameter while holding micron level accuracies. 

Completing the display is the new EUROPA eturn VS390 manual lathe. The range also features eturn Energy Management Technology (EEMT), which reduces energy consumption. The eight machine range starts with the compact eturn VS330 to the largest machine, the VS560 with its 560mm swing and up to 3m between centres. 

Mazak on another level with market entry machines

Yamazaki Mazak will be showing its ‘entry level’ machine tools on Stand 350 in Hall 20. Mazak will showcase cost-effective technology such as the CV5-500 5-axis and the 3-axis VCE Series machining centres and the QTE turning centres. 

This blend will demonstrate how the quality, technology and productivity is perfect for newcomers and seasoned experts – credit to the user-friendly Mazatrol Smooth CNC system.  The CV5-500 entry-level 5-axis machine has been designed to combine high-speed precision machining with ease of operation and its bridge construction with a fully supported trunnion table provides uncompromising rigidity for precision machining.

The trunnion table with roller gear cam on the B/C axes and roller linear guides provide a stable and robust platform and the rolling motion of the cam gear eliminates backlash. The result is an ability to contour or index in 0.0001-degree increments. Offered with a 12,000rpm 18.5kW spindle or with an optional 18,000rpm high-speed spindle, the CV5-500 incorporates a 30-tool magazine with a 1.3 second tool-to-tool ATC and the Mazatrol SmoothX CNC system. With an X, Y and Z-axis stroke of 730 by 450 by 470mm and a BT40/CAT40, the new machine can accommodate a maximum table load of 200kg. The envelope and table capacity give the CV5-500 the ability to produce everything from small to relatively large components.

Complementing the CV5-500 will be the VCE-600 3-axis VMC. Designed and built in the UK, the VCE-600 has an appealing price-point whilst incorporating a variety of new technologies. With a spacious 1.3m by 600mm table and X, Y and Z-axis travel of 1050 by 600 by 600mm, the VCE-600 has a 12,000rpm 18.5kW dual winding spindle with 119.4Nm of torque that provides exceptional power for heavy-duty milling at the low-speed range whilst at high speed, the spindle retains a high-power output. The 7/24 No40 spindle with through coolant is supplied with cutting tools by a quick-change 24 position ATC. As well as a class-leading spindle, the VCE-600 has rigid linear roller guides on all axes that emphasise the ability to perform both heavy-duty and high-speed machining. This is complemented by direct drive servo motors on all axes and fully ground pre-tensioned ball screws that deliver precision and repeatability. 

The new Mazatrol SmoothEz CNC control system on the VCE-600 with its intuitive 15inch touch screen display can offer ‘Ez Operation’ with its ability to be operated like a smartphone or tablet can be customised with the positioning of data to suit the user. For ‘Ez Setup’, the SmoothEz enables all manufacturing data, such as programs, fixture setup, machine models, tooling data and coordinate systems to be synchronised by Smooth Project Manager to SmoothCAM Ai. Having all this in an entry-level machine defines why Mazak leads the industry. Appearing alongside the machining centres will be the QTE Series of turning centre that ranges from the extremely compact QTE100SG that has a maximum machining capacity of 290mm diameter through to the QTE300SG that offers a diameter up to 350mm with a workpiece length up to 1063.5mm. The variant on show at MACH will be the QTE200SG that can accommodate parts up to 290mm diameter with a maximum workpiece length of 285/520mm. The QTE200SG is a highly compact workhorse that provides productive turning capability. 

The QTE200SG is driven by an integral 5000rpm high-performance 15kW stepless spindle motor that requires no transmission via belts, pulleys or gears. This minimises vibration during high-speed cutting to improve tool life whilst delivering exceptional power throughout the speed range. The QTE200SG has a servo-driven 12-position tool turret with a capacity for 25mm diameter tool shanks that minimises non-cutting time with its non-lifting indexing. Optionally, customers can select an 8 or 24 tool turret as well as milling spindles that can be found on the M, MY, MS and MSY variants. 

Separating the QTE200SG from other machines in its class is the Mazatrol SmoothEz (Easy) CNC interface. Similar to other Smooth controls in the Mazak portfolio, the SmoothEz defines ease of use and productive solutions with fast set-up times. For ‘Ez set-up’ the data on the machine can be synchronised with a PC in the office via Smooth Project Manager, creating virtual machines to duplicate factory floor production. As an entry-level machine, the Quick Mazatrol provides ‘Ez operation’ with its ability to quickly and easily create, check and edit programmes by displaying the 3D model of the workpiece on the customisable touch-screen display.

Complete machining

NILES-SIMMONS provides customised solutions for the machining of challenging parts across the entire engineering sector. One solution available in the UK through McDowell Machining Technologies is the multi-functional TurnMill MC-series.

One application implemented by NILES-SIMMONS involved a bespoke concept on an N30MC TurnMill machining centre for the machining of valve parts for the oil and gas industry. Featuring external, internal and face machining, the machine with a distance between centres of 4.5m was equipped with a second slide for long tools and an additional long tool magazine.

With a part length of 1.3m and diameter of 315mm, it was clad in inconel 625. The material that required a surface finish of Ra0.2 wasn’t the only challenge. All the processes needed to be undertaken behind a ’closed-door’.

Undertaking turning, milling, drilling, gun drilling, finish-boring, reaming, thread turning and burnishing with a diamond-burnishing tool, particular attention was paid to chip control with the use of high-pressure coolant.

For internal machining, NILES-SIMMONS worked with Sandvik Coromant using the 100mm diameter Silent Tools™ Plus boring bar. With this bar, it is possible to monitor ‘in-cut’ performance in real-time which contributed to the security of the closed-door-machining process. The ‘smart’ boring bar provides the operator with ‘live’ feedback to monitor the temperature, displacement, insert wear or breakage and vibration. This allows the cutting conditions to be checked, evaluated and documented during the machining process – essential for machining large components behind ‘closed doors’. 

This data is used to analyse and monitor performance and optimise the process whilst adding process security to allow the machine to stay in a stable cutting condition until the insert approaches its end of life.

When machining the internally clad components, the process security provided by the Silent Tools™ Plus means the machine, the part and tools are protected from damage – giving operators confidence in the process. Using adaptive control technologies to optimise cutting conditions, the process reliability and machining times were improved with tool life extended by more than 30 minutes. The adaptive control technology optimises the machining conditions by evaluating the level of vibration and axial loads to automatically adjust the parameters to maintain precision, finishes and component quality. These indicators enable the operator to better understand and evaluate insert tool life. The benefit is the accurate prediction of insert failure to maximise tool life and avoid costly tool breakages. In this case, the tool magazine capacity had to hold more than 400 tools with different connections as well as 15 positions for long tools in a dedicated magazine. In ‘closed door’ environments on large machine tools where the operator cannot visually gauge the changing surface finishes, vibration and chip formation, the Silent Tools™ Plus provides peace of mind, confidence and control over the entire process.

With the support of Mastercam software, Dynamic Turning was applied to optimise chip formation and control deflection forces. The clamping condition of the bar is also extremely important. For this, NILES-SIMMONS used their long tool cassettes, specifically designed to deliver rigid set-ups, clamping directly to the machine’s second slide (X2 & Z2) dedicated in this case, to long tools. 

The process was finalised with face machining, drilling, tapping, countersinking and then gun drilling a 6.35mm diameter hole through a length of 1.3m in seven steps. This included a deep hole drilling process of 205XD. 

The fully automated process also involved a highly advanced level of process automation features that enable closed-door machining without operator intervention. These features include automatic change of all tools and boring bars, in-process and dynamic measurement of the internal and external machined areas, including runouts, achieved surface roughness, automatic detection of the welded inconel layer with non-contact scanning for an optimised cycle time. It also incorporated intelligent operator guidance using an additional monitor regarding premature tool change, media filling, chip disposal and further predictive process measures.

This application underlines NILES-SIMMONS’ expertise in the field of customised machining solutions for highly complex parts and projects. The interaction of a highly developed machine with all the necessary and suitable process automation procedures, an efficient machining and tooling strategy as well as individual adaptations to the respective customer requirements is the strength of NILES-SIMMONS and McDowell Machining Technologies. 

To learn more about the smart bar capability integration on NILES-SIMMONS’ Machines visit them at MACH on stand 17-110 where McDowell Machining Technologies will exhibit the part and bar set up with all the in-depth process information.

Citizen to present new lathes

In Hall 20 Stand 150, Citizen’s LFV (low-frequency vibration) chip-breaking software will feature strongly.  The patented system is being rolled out across the company’s Cincom sliding head lathes, initially on the main spindle and more recently on the sub-spindle. To enable this, the machine models are systematically being strengthened to withstand the rigours of the momentary air cutting that creates the chip-breaking effect. There will be five Cincom machines on show at MACH 2022 equipped with LFV. A pair of Citizen’s Miyano fixed-head lathes also benefit from the technology.

A total of 12 barfed, sliding and fixed head mill-turn centres will be demonstrated under power on the Citizen stand, including an automated production cell with integrated loading and unloading. Making its world debut will be the new, 20mm bar capacity Cincom L20-XIIB5LFV. The series-5 Cincom M32-VIIILFV will appear for the first time at MACH, as will the fixed head Miyano BNE‐65MYY. Both have been redesigned to offer more power and flexibility and have been fitted with the latest Mitsubishi 800-series touchscreen control. 

On show for the first time will be a Cincom L32‐XLFV with integrated, high-speed laser cutting, a capability that was originally developed for efficient production of apertures in thin-wall stents on smaller sliding head lathes. There will be a Cincom D25-VIILFV exhibited for the first time at MACH with the proprietary chip-breaking software. As on many other sliding head lathes manufactured by Citizen, the user has the advantage of being able to remove the guide bush for more economical material usage when producing shorter components up to typically 2.5 times the bar diameter. A further highlight will be a Cincom A20‐VIILFV, the first to be equipped with multi-axis LFV software in a Fanuc-based Cincom control. 

The exhibition will also feature the first UK showing of the 12mm bar capacity Cincom L12-XLFV with five rear-facing static and driven end-working tool positions and the addition of a Y-axis on the counter spindle to mirror the main spindle’s 3-axis movements. 

From the Miyano stable, the ABX-64THY with 80mm bar capacity and an ANX-42SYYLFV with FANUC control will also make their debuts. Making another appearance at MACH to illustrate automated chucking will be the twin-spindle Miyano GN-3200W equipped with a high-speed loader capable of achieving high levels of productivity. The compact, rigid, thermally symmetrical machine offers a wide choice of infeed/outfeed devices, single or double high-speed gantry loaders, and transfer and turnover units.

Rounding off the exhibits on the stand will be an educational area explaining the latest Citizen software. It includes Eco Function hybrid technology that automatically saves energy through the intelligent use of power during non-cutting periods, underpinned by clear, on-screen graphical information showing present, maximum, cumulative and historical power consumption values. The next iteration of Alkart Wizard for off-line programming will also be in evidence, as well as Citizen’s Industry 4.0 capabilities encompassing the latest machine networking and monitoring functionality.

Dugard to demonstrate 5-axis excellence

At MACH, Dugard Machine Tools will be showcasing a raft of new machines – many of which will be receiving their MACH debuts. On Stand 640 in Hall 20, Dugard will be introducing four new machine tools on its stand. 

With one of the most diverse portfolios of machines in the UK, Dugard will be introducing the Kitamura MedCenter5AX 5-axis vertical machining centre for fast precise machining. Complementing the MedCenter5AX will be the larger Dugard GTX-620 5-axis machining centre. With vastly different configurations, the two machines will highlight just a small element of the expansive Dugard milling range. 

The Kitamura MedCenter5AX 5-axis VMC is an extremely compact and versatile machine. With an X, Y and Z-axis travel of 254 by 330 by 330mm over a 170mm diameter table, the machine incorporates a 30 to 30,000rpm spindle with an HSK-E40 spindle taper that is connected to a 40-tool ATC that can change tools in just 1.5 seconds. Providing a rapid traverse of 60m/min and table rotation of 200rpm on the A and C-axis and a pallet change system, this machine will attract attention at MACH. 

For the machining of larger components, Dugard will be introducing the GTX-620 simultaneous 5-axis machining centre. With an X, Y and Z axis of 620 by 520 by 460mm and the capacity to accept workpieces up to 700mm diameter on the table, the GTX-620 complements the smaller Kitamura MedCenter5AX. Available with a FANUC or Siemens 840D CNC control system, spindle power up to 22kW a BT40 spindle taper and a 12,000rpm spindle motor, the GTX-620 is a powerful solution. 

The B-axis tilts from -50 to +110 degrees with the C-axis capable of rotating a full 360 degrees to 0.001degree. Dugard can equip the machine with a range of optional extras. The options include linear scales, optical encoders, laser or contact tool length measurement, chip flushing, HSK63 20,000rpm or a 15,000rpm direct-drive spindle and much more. Dugard will also be introducing fixed and sliding head turning centres at MACH.

Lots to see from XYZ at MACH

XYZ Machine Tools has decided to expand its presence with a second stand in Hall 17 Stand 200 that will be used to introduce the latest innovations in toolroom machining centres that will highlight the transition from bed mill to machining centres. 

On the main XYZ stand Hall 18 Stand 130, several machines will make their UK exhibition debuts including the brand new XYZ SS 65 sub-spindle lathe, a first for XYZ Machine Tools and one that is generating lots of interest. Introduced due to demand from customers looking for increased productivity and reduced spindle downtime the XYZ SS 65 features a 16.5kW 4000rpm main spindle with 65mm bar capacity and 200mm diameter chuck as standard. This is complemented by the 11kW 5000rpm sub-spindle with a 52mm bore and 150mm chuck. The German-built Sauter 12-position turret has live tooling at every station, with 100mm (+/-50 mm) Y-axis travel. Contouring is facilitated by the C-axis on both spindles which are equipped with a brake to allow substantial milling cuts to take place (See Page 50).

Also making its MACH debut is the XYZ PROTURN RLX 780 lathe. The sheer scale of this machine has precluded it from being shown before. Weighing in at 8600kgs the machine features a swing over the bed of 780mm and a distance between centres of 3m. The spindle is powered by a 32kW motor with the gearbox providing two speed ranges from a low of 20rpm through to 1300rpm. Control is from the latest RLX ProtoTRAK system with its touchscreen interface and software features that allow the user to go from drawing to a finished component in the shortest possible time. The features include gesture control, constant surface speed, electronic handwheels to generate tapers, radii and fillets manually, enhanced ProtoTRAK assistant and the TRAKing® feature. The faster you wind, the faster it machines. Stop or reverse the handwheel and the machine does the same.         

Other machines at MACH will include the entry-level ProtoTRAK mill, the KMX 2000, a selection of RMX ProtoTRAK bed mills and RLX ProTURN lathes, linear rail and heavy-duty and high-speed vertical machining centres will be well represented including an XYZ 1060 HS machine equipped with a Detron 5-axis system. Turning centres on show will be the XYZ CT52 LR with linear rail technology and the XYZ SS 65 sub-spindle lathe. Completing the machine range on show will be the XYZ UMC-5X simultaneous 5-axis machining centre, which since its introduction has been very well received by customers across a range of industries. 

If previous MACH exhibitions are anything to go by the XYZ Machine Tool stand will be extremely popular and while demonstrations are freely available, there will be times when all machines are busy. To overcome this, the stand will also feature four stand-alone pendants with RLX and RMX ProtoTRAK controls on them. These will be available to highlight the ease of use of the ProtoTRAK system and emphasise how this control can simplify production and increase productivity and profitability as 1000’s of existing users can testify to.  

Supporting Industrial Prosperity

As the headline sponsor at MACH, Lloyds Bank has a history in the manufacturing sector that dates back to its 1765 foundations. Ahead of the show, Rhys Williams spoke to David Atkinson, UK Head of Manufacturing and Regional Director for SME and Mid Corporate Banking Midlands & South Wales to discuss what it is doing to support industry.

Serving the Sector

With more than 34 years working at Lloyds’, primarily with Midlands-based SMEs, David’s fascination with manufacturing dates back to his early work experience days at an engineering company. “When we had a new Chief Executive at the end of the last recession, our core purpose to serve our communities and help Britain prosper came to the fore. With all our brands, we have over 26m customers. When it comes to helping the country to prosper, it comes down to employment, well-paid jobs, exports and infrastructure, innovation and skills development. Manufacturing has 2.7m direct jobs with upward of 7.5m jobs indirectly linked through supply chains. Whilst the direct manufacturing contribution to GDP is 10%; with the indirect and induced impact, manufacturing is responsible for around 23% of the economy. We did some work with the MTA and Oxford Economics to prove this. So, if you want to get behind a sector that helps Britain prosper, with 7.5m jobs, 23% of GDP, 15% of business investment and 65-70%+ of business R&D and nearly half of all UK exports – manufacturing is an industry we are proud to support.”

Why do you sponsor MACH?

“This will now be our 12th year of being the headline sponsor, we see the MTA as a strategic partner for supporting industry. When you have 20,000+ industrial visitors, it is a fantastic opportunity for engineers to network . We know that when we put events on for manufacturers, the best part of the event for delegates is having the opportunity to talk to like-minded engineers facing the same challenges and opportunities. MACH is the biggest event in the industry for getting engineers together to network. The exhibition shows the latest technology and we know that investing in this technology will improve productivity, remove waste, remove carbon, create new jobs and open new market opportunities – and we want to support the MTA in bringing this to market to drive productivity.”

What is the remit of the manufacturing division of the bank?

“My remit over the last 10 years has been to design, lead and launch a proposition to specifically support our SME and Mid Corporates Manufacturers. When we started talking to manufacturers, the one thing engineers wanted was bankers that understood the industry – that resonated with me. Another challenge manufacturers are faced with, is a shortage of skills. So, we need to think ‘how we can support manufacturers around skills?’. Those are the two key parts we said we would invest in, to demonstrate our support of UK manufacturing. Now, we send our employees to the Warwick Manufacturing Group (WMG) for training through the University of Warwick, and they understand manufacturers much better. In terms of skills, as we emerged out of the financial crisis of 2008, Vince Cable launched the High Value Manufacturing Catapult (HVMC) initiatives to replicate the Fraunhofer Institute in Germany that connects industry with academia.”

“In terms of the UK’s reputation, once we have it on the production shop floor, we are brilliant at producing high-quality products, but there is a gap where our ability to take ideas into production has sadly fallen. The Catapults’ have been set up to connect industry and academia, so we can turn these ideas into products that can be ‘made in the UK’ and exported. As a sponsor of the MTC in Coventry, we have a responsibility to take the MTC capability to the factory floors in the local regions, but if the manufacturers don’t have the skills, there is little point in providing access to the latest technology. So, opposite the MTC in Coventry is the Lloyds Bank Advanced Manufacturing Training Centre. We put our money where our mouth was in 2015 with a £1m a year, 10-year sponsorship to upskill graduates, apprentices and engineers. We are on track to deliver around 3,500 upskilled engineers and apprentices through our sponsorship at the AMTC.” MTC SME support service information can be found here: https://the-amtc.co.uk/lloyds-sme/

“To push this further into industry, the MTC has a team of highly skilled and industry experienced engineering advisers that work with small businesses where they have challenges on their factory floor. All of our local banking teams in the communities are aware of this facility. So, we have upskilled our team, we have committed to upskilling the industry and the next thing on our agenda is sustainability.” More on the specialist manufacturing support services can be found here: https://www.lloydsbank.com/business/industry-expertise/manufacturing.html

Environmental responsibilities 

“We know businesses investing in sustainability are growing faster. We know there are benefits in terms of future employability, either in local communities or with youngsters that are becoming choosy on companies they work with based on their environmental credentials. We held a series of roundtable discussions with SMEs and we have just published a report on the challenges and opportunities to help our SME manufacturers on this journey. Equally, we asked what policy changes the industry felt that we needed to put our weight behind with government. The report (From Now to Net Zero/Business/Lloyds Bank) covers challenges and opportunities, but it also has insights from industry that will help other businesses. We have also incorporated a five-point plan to help SME manufacturers on their sustainability journey. Another thing we are trialling is carbon calculators, as most businesses don’t know how to measure and calculate their carbon footprint – we will be launching tools to help later this year.”

The resilience of the industry

“The industry is extremely resilient, and at present, SME manufacturers are facing inflationary pressure, geopolitical issues, energy price rises, material availability and a whole host of other challenges that have been compounded by the pandemic. The good news is that recent industry reports indicate around 98% of manufacturers are saying they are looking forward to growing this year, or at worst, sustaining what they have with only a small percentage expecting a decline in 2022. So, businesses are ambitious, confident and showing their agility to get through the challenges.”

Reshoring

“There is also a huge opportunity for re-shoring and the growth and profitability for business increases when companies export. We have a trade portal that enables businesses to research the HS code for export for specific products. If manufacturers enter a HS code, it will tell them what countries are buying their products, which are growing and it will even inform manufacturers which companies in those countries are buying the products they manufacture. It will also provide insight into all of the cultural challenges, documentation and information on what a business needs to do, to export to these countries. The portal will also inform businesses what tradeshows relate to the potential customers in those countries, so manufacturers can even have exhibition stands at the overseas tradeshows. This service is completely free of charge to our clients.” See more: https://www.lloydsbank.com/business/resource-centre/international-trade-portal.html

Where else are you investing? 

“We try to be the most impactful that we can be. We were also headline sponsors at the National Manufacturing Summit at the MTC in February where our Group Chairman delivered a speech to launch our manufacturing sustainability report.”

“Moving forward, we try to provide a simple and efficient online digital banking system that across the group now has upward of 17 million digital users in the UK. We are also engaging with businesses through social media to bring lots of thought leadership and innovation. We also write directly to our SME Manufacturers several times a year to share insight and helpful guidance.  The subject matter will change from what we can do to help prevent fraud, relevant events and how to best access and utilise finance. We also have specialists that work with manufacturers to help them buy machinery and specialists that focus purely on international trade.” 

How has the pandemic changed

the landscape?

“The pandemic has impacted businesses differently. Like every industry, you will have winners and losers. We help those winners to maximise advantage through the pandemic whilst the companies that have been struggling, we find a way to help them get through the pandemic. Whether this is restructuring finances, capital repayment holidays, traditional or emergency funding through the government such as the BBLS and CBILS. Through these initiatives, we have helped companies obtain billiions of additional funding. It thankfully remains a generally a very benign environment, in the main the resilience and agility to reorganise, restructure and operate with social distancing and things like multiple shifts – it has just been incredible endurance and agility.”

“We are now seeing a lot of companies investing in new plant and machinery and taking the opportunity to restructure their businesses and reshape the factory floor to look at new opportunities, and even taking sustainability into account.” 

“We also noted fairly sustained investment in plant and machinery. As we have exited the pandemic, we have seen the working capital funding start to grow again. This is because as businesses have exited the pandemic faster than expected with strong economic growth, they do risk running into overtrading where they do lots of business, but run out of cash to fund the raw materials and pay staff. Here, we have to support businesses to avoid this overtrading scenario. Historically, more businesses have risked failure as they exit a recession and run out of cash due to growth rather than failing as they enter a recession. The other trend in traditional ‘term debt’ was driven through pandemic funding through the CBILS and BBLS loans – this means more companies have taken on more debt for emergency funding but thankfully many tell me that they haven’t utilised it all, helping their liquidity as they start to grow again.” 

Lights, Camera….. and Action!

After a four year wait, the MTD team is excited to be returning to the MACH exhibition to be the promotional vehicle of choice for the latest technology the industry has to offer.  With the pandemic preventing the MTA from fulfilling its bi-annual slot in 2020, the show in April promises to be an absolute cracker. At previous MACH exhibitions, the MTD team has dedicated each day of the event to one specific ‘MACH Live’ participant. This year we are doing it differently! By Rhys Williams

What are we doing and why? 

This year, we have made the ‘MACH Live’ platform different, to better reflect the exhibition and its participants. With no MACH exhibition over the last four years, just consider the gargantuan number of new technologies and machine tools that have been developed that nobody has been able to see. Just focusing upon one company each day throughout the event wouldn’t be serving our viewers, the industry or the exhibition justice. So, at MACH 2022, MTD will have our full team of reporters, cameramen and the behind the scenes magicians that make it all work. Like our MTD magazine team, the digital crew will be reporting on all the activity that is taking place throughout the week. 

However, for businesses fortunate enough to pre-book their slots with MTD, we will be undertaking ‘MACH Live’ broadcasts direct from manufacturers’ exhibition stands at the show. The live streams will be broadcast across MTD’s YouTube and LinkedIn channels as well as on the MTD website and App with the footage emailed to more than 20,000 engineers after the event. With more than 1.2 million social media impressions every month, this will be a huge opportunity for our ‘MACH Live’ participants to reach engineers that couldn’t make it to MACH or manufacturers that simply didn’t get a chance to get around every stand at the show. Filling these prestigious slots will be recognised brands such as Hexagon, Star, Ceratizit, Hainbuch, NCMT, Matsuura, Sodi-Tech EDM, the Hoffmann Group, Intoco, Dugard, Schunk, Haimer and Chester Machine Tools. 

With allocated timeslots, our schedule for Monday the 4th of April will include Hexagon, Star, Ceratizit and Hainbuch. Kicking off the first live slot will be Hexagon where MTD will be filming the complete software portfolio that demonstrates how its solutions help engineering, production and quality teams adapt more quickly to changing requirements and improve productivity from design to production and inspection. Every manufacturer knows that even the best-looking design can fall flat when the rubber meets that often-bumpy road of production. Making the transition from design to manufacturing without computer-aided design (CAD) software that helps meet design requirements specific to manufacturing can lead to costly delays. Now available to all of Hexagon’s CAM software subscribers, DESIGNER provides CAD and model preparation tools that speed up adjustments that ensure the manufacturability of parts. The software includes a variety of productivity-boosting features that can be easily utilised by new and experienced personnel. 

Making their debut is Hexagon’s computer-aided engineering (CAE) team. It will demonstrate 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. It’s difficult and time consuming to achieve accurate measurements, especially when several tools and expert users are required to create usable, high-quality point clouds. Making these workflows easier by reducing the required steps can save significant time and resources.

MTD will also look first hand at how quickly and easily a part can be scanned for reverse engineering using Hexagon’s AS1 3D laser scanner. The AS1 is used to scan a part directly into reverse-engineering or CAD software as a high-resolution point cloud, where the part can be prepared for machining or other processes. 

The company will also be showing an Absolute Tracker, which provides absolute positioning to the AS1, 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. 

The MTD ‘live’ broadcast schedule for MACH week

Making the most of your machine tools can be tough without CAM software capable of safely and efficiently programming machinery. So, Hexagon will demonstrate the latest developments from EDGECAM, WORKNC, NCSIMUL and also ESPRIT – which is now integral to the Hexagon portfolio.

At the heart of the stand, a Hexagon GLOBAL S CMM will demonstrate 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.

Following the Hexagon slot, we’ll be on the Star Micronics GB stand filming the latest model on display, the new SL-10 sliding head lathe that follows the UK premiere of the smaller SL-7 at Star GB’s event held in November. Capable of machining bar as small as 0.8mm diameter, the SL Series has been designed for manufacturing miniature components. Both models offer 6 turning tools on the main side and up to 5 cross-working tool positions, of which 4 tool positions are available for cartridge attachments such as thread whirling, slotting, gear hobbing, angled drilling and polygon units. 

Another model that we’ll be looking at is the SX-38. The company’s 38mm diameter machine will take centre stage to show its three-channel machine, offering a total of 12 axes that is developed to suit complex mill-turn applications with its versatility, accuracy and performance.

The most popular model in the Star machine range has also been revamped with the third-generation SR-32JIII succeeding the SR-32JII. On Star GB’s stand will be the versatile SR-32JIII Type B variant that offers a range of benefits including improved rigidity, enhanced swarf clearance, upgraded ergonomics and the inclusion of a sub-spindle flush pump as standard. In addition, Star GB will be demonstrating a range of models up to 42mm diameter capacity across its SW, SR and SB model ranges. We’ll also return to the Star stand on Wednesday to make sure our viewers don’t miss a thing.

From 1 to 3pm, the team will be on the Ceratizit stand to film the live prize draw for a Hope HB130 mountain bike, valued at over £6000. As well as showing its latest cutting tool innovations at MACH, Ceratizit UK & Ireland will also be using MACH to raise valuable funds for its two chosen charities, the British Heart Foundation and Cancer Research UK. To be in with a chance of winning the bike, which will be custom-fit to the winner, simply make a minimum donation of £10.00 at https://www.justgiving.com/teams/WNTEVENTS where you can select which of the two charities you want to support. The winning entry will be chosen on the first day of MACH on the Ceratizit stand 18-210 at 2:00pm by World, Olympic, European and Commonwealth cycling champion Katie Archibald MBE. In addition to making the draw, Katie will be on the Ceratizit Stand from 10:00am through to 3:00pm, where she will be happy to chat, sign autographs and, be available for photos.

Katie’s presence on the Ceratizit stand marks her return to competing with the UCI Women’s Continental team CERATIZIT-WNT Pro Cycling on a three-year contract. As part of the team, Katie will compete in the Tour of Britain, but her focus will be track cycling to win more gold medals at the Commonwealth Games, the World Championships in 2023 and the Paris Olympics in 2024. For many of her races in the velodrome, Katie will be riding the Hope Technology/Lotus/British Cycling track bike that has been manufactured at Hope Technology’s Barnoldswick factory using tooling supplied by Ceratizit.

The MTD crew will also be filming technology from the four competence brands of Ceratizit, WNT, Komet and Klenk and the latest innovations in cutting tool and workholding advances. From the turning stable, MTD will be looking at the new CTCP115 CTCP125-P and CTCP115-P grades developed for the machining of ISO-P grade steel.  At the end of its life, 

Ceratizit has integrated a new indicator layer into the special multi-layer Dragonskin tool coating that highlights when the tool life is close to its limit. 

With regard to milling, MTD will be taking a closer look at the Silverline range of solid carbide end mills that is available in a variety of styles including Torus-style cutters, end mills with corner radius and standard end mill forms. The range comes with the latest Dragonskin coating and advanced cutting geometries that help deliver performance in terms of metal removal, enhanced cutting data and tool life. 

The new threading line will be demonstrated with the SGF solid carbide thread milling cutters from WNT that are now a standard item from the Ceratizit catalogue with next day guaranteed delivery. The SGF thread mills are available in a range of sizes with most conventional thread forms.  

Our team will also be taking a closer look at the drilling line that will include the latest Komet KUB Pentron CS (Cartridge System) indexable insert drill. This latest addition to the KUB Pentron range adds to the existing range that covers diameters from 14 to 46mm, with the new CS variant offering cutting lengths of 3XD. The KUB Pentron CS is suitable for universal applications and is now part of the standard Ceratizit Group portfolio. 

Workpiece clamping is often overlooked, especially when looking at straightforward workpieces, so the MTD team will be taking a closer look at the new SBF-3 stationary 3-jaw chuck from the WNT Performance range will make a difference.

The SBF-3 3-jaw chuck is compatible with both the MNG (mechanical) and PNG (pneumatic) zero-point clamping systems, a feature that reduces set-up and non-productive time to a minimum. 

From 3 to 5pm, we’ll be finishing the day on the Hainbuch stand. Hainbuch will show the new Hainbuch System, a complete gamechanger for manufacturers looking for efficient and flexible workholding. Stand H20-447 will be crammed with exciting new technology and MTD will be there to film it all. 

The Hainbuch System is a quick-change innovation that adapts to your needs, allowing manufacturers to clamp 1000 different workpieces without the need for a multitude of solutions. With the Hainbuch System engineers now only need one basic clamping device, a chuck or a stationary chuck that remains on the machine tool. Whether it is OD, ID, prismatic components, jaw, magnetic or clamping between centres – the Hainbuch System provides a solution without any compromises. 

The workpiece determines the adaptation required and converts your basic clamping device for the particular application. This incredible solution reduces set-up times substantially while increasing flexibility and making it possible to easily squeeze in fast turnaround jobs – making sure you are optimally prepared for every clamping situation, whether it is turning, milling or grinding. The system includes the exciting Toplus Premium Chuck. The Hainbuch portfolio of chucks has always been very precise and once the chucks are aligned, the runout is near to zero for repeat clamping. 

With the Toplus Premium Chuck, Hainbuch guarantees a runout of ≤5μm without alignment, regardless of which clamping head is used. By utilising the new Toplus Premium Chuck with the associated premium clamping heads and by clamping against the workpiece stop, this level of accuracy is always achieved. 

Tuesday will also be a jam-packed day as we head to the NCMT stand. With such an impressive array of products, we’ll also be returning to NCMT on Wednesday morning too. NCMT has two stands in Hall 19 on which it is promoting its sole agency machine tools. Stand 120 is devoted to demonstrating Okuma turning and machining centres as well as its Industry 

MACH ready to display new technologies

MACH 2022 is set to be the most significant gathering of manufacturers this year and it will highlight some of the most important issues facing the industry, such as sustainability and the drive to net zero – as well as a huge display of new manufacturing technologies. 

The post-pandemic manufacturing revival, the drive to Net Zero and the opportunities offered by decarbonisation, the development of innovative technologies shaping manufacturing and a special focus on 3D printing, are all themes for the show.

The exhibition could not be better timed for the sector. The Manufacturing Technologies Association (MTA), which organises the show, believes the growing optimism will see bumper levels of business during the show. Exhibitors too are excited at the prospect of showcasing their latest products to buyers ready to capitalise on the current financial incentives such as Super Deduction and AIA available to businesses investing in capital assets.

James Selka, CEO of the MTA, said: “With the UK economy growing above forecasts for 2021 and the CBI predicting plans for spending on machinery over the coming twelve months have improved considerably, the timing of MACH could not be better. To make step-change improvements, you only need three things – Technologies, the skill to acquire and deploy those technologies and the finance to make it happen. There has never been a better time to accelerate investment in UK manufacturing and with MACH 2022 bringing together the latest manufacturing technologies, it will be the perfect place to come and view the best new machines on the market.”

The CBI’s latest survey indicates plans for spending on machinery over the coming 12 months have improved, with the percentage balance (+26) standing at its highest level since April 1988. Four consecutive double-digit positive balances in a row are exceptionally rare and represent a strong recovery.

This year’s show will focus on the best of the manufacturing sector – the digital factory, additive manufacturing, new automation solutions and connected manufacturing processes, power by the hour and cost-efficient solutions that will improve production processes over the next decade.

Resolving the challenges of energy prices, labour costs, skills shortages, raw materials, supply chain disruption and tackling the green agenda by seizing the opportunities posed by decarbonisation, will also receive special focus. 

AMRC Tooling Clinic

Debuting at the 2022 show will be a special ‘Tooling Clinic’ run by the University of Sheffield Advanced Manufacturing Research Centre (AMRC). The Tooling Clinic will enable visitors to identify the right solutions for them through open discussion of challenges within their tooling applications, cutting strategies, parameter optimisation, virtual machining and other high value manufacturing methodologies. 

AMRC engineers will provide presentations on key discussion areas and signpost visitors to the exhibitors who can best address their requirements. 

Discussion topics will include: 

-Process costing and parameter optimisation

–Virtual machining for CAM iteration and process optimisation

–Cutting strategy for thin parts

–Aluminium, titanium and inconel best practice

–Down selection of tooling geometry using virtual machining

–Use of non-traditional substrates

–Focused support for SMEs

–Tool holding technologies

–Micro machining

–Machine tool dynamics

Visitors can make an advance appointment, highlighting their challenges or identifying options from the list of discussion topics. Appointments can be booked at: www.machexhibition.com/tooling-clinic 

Seminar Programme

MACH 2022 will feature a strong seminar programme with session speakers focused on delivering intuitive and engaging presentations reflecting the themes of the show.

“The global shift towards greater sustainability has gathered significant momentum during the past four years and the drive to Net Zero and the opportunities offered by decarbonisation will be a core theme of MACH,” said Mr Selka. 

“This will be reflected in the speaker programme, with several speakers basing their presentations on this subject. Hopefully, this will encourage visitors to discover more about the opportunities provided by these new technologies.”

The programme begins at midday on Monday 4th April, with Katherine Bennett CBE, Chief Executive of the High Value Manufacturing Catapult, delivering the keynote speech in which she will address two of the key themes of the show – the importance of sustainability in manufacturing and the drive to net zero. Professor Juergen Maier, Co-Chair of Made Smarter, will be picking up on this theme when he delivers his presentation ‘Delivering a Responsible and Decarbonising Made Smarter’ on Wednesday 6th April.

On the following day, John Pearce, CEO of Made in Britain will be chairing a panel discussion entitled ‘Race to Net Zero – Destination or Dream’ which focuses on sustainability. 

Key market intelligence will be provided by Rhys Herbert, Senior Economist at headline sponsor Lloyds Bank, who will deliver ‘UK Manufacturing – Better Times Ahead’ on Thursday 7th April. In this presentation, he will provide an overview of the current state of the UK manufacturing sector and the economic opportunities that lie ahead for manufacturers. 

Additive Manufacturing will be the subject of several presentations. On the Wednesday of the show, Kieron Salter, CEO at the Digital Manufacturing Centre will discuss how to utilise the opportunities posed by AM to develop cost-effective production. This will be followed by Ed Cant, Advanced Research Engineer at the Manufacturing Technology Centre, who will discuss The Future of Tooling in Additive. 

Stuart Watt, Advanced Research Engineer at the Manufacturing Technology Centre, will finish the AM discussions by outlining the disruptive technology of 3D printing and where to begin.

On Thursday, a familiar face to MACH, David Holmes, Director of Operations and Technology for Air BAE Systems, will be talking about the requirements BAE needs to remain competitive in a global market. In line with one of the key themes of the show, Lugano Kapembwa, Co-Founder and CEO of Loopcycle, will use his presentation to help steer the B2B sector through the unlocking of the circular economy. 

Spaces for each session will be limited and available on a first-come, first-served basis. 

Education & Development Zone

MACH will once again have a strong focus on encouraging more young people into the industry, with special displays and a dedicated exhibition zone showcasing the changes that are taking place within manufacturing and highlighting what makes it one of the most exciting industries to be involved in.

The Education & Development (E&D) Zone, sponsored by Sandvik Coromant, will feature special displays from Airbus Defence & Space, University of Wolverhampton Formula 3 Race Team, Vex Robotics, the Bowers Group Mobile Metrology Centre, F1 in Schools and the Engineering Development Trust (EDT), a nationwide educational charity which offers young people (9-21 years) active learning experiences in STEM-related careers.

-Airbus Defence & Space will be displaying its ExoMars Rover ground demonstration model, ‘Bruno’. Bruno is the Earth-based testing model of its counterpart the ‘Rosalind Franklin’ Rover, which will search for life on Mars. The ExoMars will be demonstrating how it can navigate the surface of Mars, while staff from Airbus will be showing how they communicate remotely with the rover and will be answering questions from young people keen to learn more about engineering.

-The University of Wolverhampton Formula 3 Race Team provides university students with industry experience by working as part of a professional team in a competitive Motorsport environment. They will be displaying a selection of cars from their race team, which includes a Formula 3 Dallara F308 with a Honda Mugen engine run in the F3 Cup, two Plus 4 Clubsports run in the AR Motorsport Morgan Challenge, a Formula Renault 2.0 previously run at the 2015 Monoposto 2000 Championship and their IMechE Formula Student car.

-VEX Robotics is an educational robotics company with a significant presence from Early Years, right through every Key Stage and into University, both for classroom use and extra-curricular competitions. Its VEX IQ and VEX V5 are also used in two of the world’s largest robotics competitions with thousands of teams competing in events every year. At MACH 2022, it will be running workshops using its VEX V5 Workcell Factory Automation solution. 

-F1 in Schools is a STEM competition with a difference. Aimed at students aged nine to 19, participants are presented with the chance to work in a close-knit team, where everyone takes on a role to suit their skills. Teams are challenged to create and race their vision of the F1 car of the future, to official Technical Regulations, set out by a rule committee led by legendary F1 Engineer Gary Anderson. 

-The Engineering Development Trust aims to give young people the opportunity to gain knowledge and exposure that will help them make decisions about their future and inform young people how STEM is relevant, interesting and leads to a rewarding career.

Metalworking Village

The Metalforming Machinery Makers’ Association (MMMA) is capping another major year of growth by taking over 650m² of space at MACH, allowing more than 23 members to showcase their services and technology. 

Visitors will be able to enjoy live demonstrations of machinery and take part in technical discussions that will help them improve production processes, remove bottlenecks, whilst also increasing orders and profitability. 

Focused Zones

As with previous shows, the exhibition will be laid out in a series of interconnected zones covering virtually every facet of the manufacturing technologies industry. 

These include:

-3D Printing & Additive Manufacturing

–Automation for Manufacturing

–Digital Solutions for Manufacturing

–Grinding & Adhesives

–Lasers for Manufacturing

–Logistics for Manufacturing

–Measurement & Inspection

–Surface Finishing & Component Cleaning

–Welding 

“MACH is such a fantastic event for both exhibitors and visitors. Showcasing live, digital production systems in one space, it is not to be missed. Hundreds of millions of pounds worth of business are discussed, secured and completed at the exhibition, making it the must-attend event in the UK manufacturing calendar,” added Mr Selka.

Engineering Supply Chain Show

There is also the new exhibition that MTD magazine covered in our January issue. Launching for the first time at MACH 2022, it will highlight another of the show’s core themes – the opportunities that can be found within the UK supply chain. Sponsored by Lloyds Bank and the Engineering Industries Association, The Engineering Supply Chain Show is where engineering and manufacturing buyers can go to source world-class suppliers, exclusively in the UK engineering and manufacturing supply chain.

“The UK Supply Chain Zone has always been one of the busiest areas of the MACH show and given the abilities inherent in the UK SME manufacturing sector, it makes sense to expand the zone into a show-within-a-show,” said Mr Selka.

He adds: “With more and more OEMs and Tier 1 companies looking to reshore operations and source component supply from within the UK, then the ability of the various UK supply chains to facilitate this has never been more important. It is why this new exhibition will provide a focused showcase for these in-demand products and services.”

Make sure you measure-up metrology options at MACH

I would like to thank the MTD Magazine team for inviting me back to write more articles after a break of 18 months. My last article, the last of a 3-part measurement series was written at the end of 2020. In that same year, we all had to miss the planned MACH 2020 show due to Covid. April will see the return of MACH, and I, like the rest of the industry have missed the showpiece event. The theme of this year’s show is skills and development, something close to my heart and a necessity if we are to meet the needs of smart manufacturing and its productivity promise. By Ian Wilcox

My area of expertise is metrology and like many lifelong engineers, I could fill pages about the issues surrounding skills development in my discipline. Skills shortages are not new. It’s been one of the challenges since well back into the last century and has never really been fully resolved.  You could make a convincing case that when the third industrial revolution was strongest throughout the 1970s, we started to lose our way. Our manufacturing engineering sector was on the back foot financially and government support for the sector was ebbing away. This double whammy naturally starved and weakened many of those that supplied engineering skills training, particularly private companies and colleges. In every decade since, successive governments have tried to reignite it, but…..well, what do you see? 

But now is the time and opportunity to move forward, not look back.

Metrology skills are not the only factor in good industrial measurement, as important as they are. Having good measurement technology, sound application and close cooperation with other disciplines such as production and design are also factors that enter the mix. In addition, we should also look at that often missing ingredient, what is the objective and the plan to achieve good metrology. Each is as equally significant as the other.

It is easy to fall into the trap when a company expands production or, a measurement system needs replacing, to just go out and buy like for like. But before you do, ask yourself, is it just the technology we need to upgrade? At MACH, you will certainly see many examples of innovative and ingenious technology, but do you have the skills to select and optimise the usage of the one technology or the mix of technology that suits your measurement applications best. Is the new measuring system just replacing the old, outdated measurement system with no other changes? Or is the system fitting in with how you currently work, rather than being considered as part of a wider opportunity? 

For example, if a company bought a new machine tool or moulding machine, surely you would use all of its improved benefits to optimise productivity. You would look at the whole production line, cell or process and make the adjustments to the whole – you would not install and under-utilise this new system so that you don’t have to change the wider process. Wouldn’t you have a plan and take the wider opportunity that the new technology offers? Is that also the case with your measurement equipment? 

In today’s manufacturing companies, it is common to have measurement hubs. Measurement systems, particularly coordinate, software-driven systems are often a large investment. Their capacity is often greater than the needs of any single production line. By having hubs or even one central measurement room, if demand is sporadic or environmental requirements are specific and costly, OEE of equipment and operators can be kept high by centralising the measurement systems and skills. 

However, production parts are diverted away from their production added-value activities and join the queue at the hub. The data you need from measurement, is not always quickly returned and so lagging true process control. These hubs are often not a process-driven place, usually having an uncontrolled irregular flow of parts with no production processes other than some basics. No lean thinking here.

As a hub, the measurement technicians and inspectors that staff it, often report to quality. There is no connectivity with any one production line and so, no personal investment in focused productivity. Production constantly questions results when they challenge what they anticipated. Trust between measurement and production breaks down. Sometimes however personal relationships can obscure the reality of that disconnection, good people can make things work.

By having multiple feeders of parts to measure, from several lines and even buildings to service, workflow becomes difficult to manage and ‘investigations’, ‘rechecks’ and fixture changes all disrupt the flow, causing bottlenecks. The irregular return of results causes inflated unproductivity when issues do occur. All adding more heat to the ‘them and us’ disputes. I paint a bleak picture, but it’s one I have seen regularly enough. It is a challenge for some, but not an impossible one. 

Use lean, create processes and their subsequent procedures, try to engender productive thinking in the hub and when you need to replace measurement equipment, ask yourself ‘like for like’ or could you solve some of the wider issues of measurement and productivity with alternative use of technology. Try to bring measurement and its underpinning metrology closer to production, both in terms of cooperation and in physical distance. The closer it gets, the more its processes can be integrated with the flow of production. 

Companies that are now looking closely at productivity are considering modern technologies both as part of normal regeneration, but it has also been speeded up by the realities exposed by the pandemic. The pandemic randomly took skilled people out of the business for days at a time, not only taking resources when it was needed, but also their knowledge and experience was temporarily removed. It exposed a reliance on an under the radar network of unrecognised skills and ‘make it work’ relationships. The disruption this caused was felt by many, but not always fully appreciated and recognised by all. There is now a new drive to better control and understand processes and skills to catch up with automation. 

The forward leap in measurement technology means a quite different MACH show to the ones you may remember, especially if you have not visited for a decade or more. As well a wealth of new types of systems based around photogrammetry and laser arrive, there are more alternatives to applying a traditional CMM in certain applications. You will now also see that culmination of ‘Industry 3.0’ as many will be demonstrating robot loading and sensor handling, paving the way for the journey into ‘Industry 4.0’ or smart manufacturing as some prefer. Manufacturers need to challenge their thinking over integrating measurement into production. Engineers need to consider cell or line-based measurement that is included in the Takt time to drive process control and build added value with productivity gains. The opportunities currently in front of UK manufacturing are the pull, the need to catch up quickly is the push.

The journey from a handshake to a fully automated system

To give Danish KP Komponenter A/S a foothold in the Swedish market, the company acquired Trestads Precisionsmekanik AB. In 2019, the name changed to KP Components AB, and a new machine hall with a new highly automated production system was implemented by Fastems.

KP Components initially started in 1987, now the company has 30 employees and a production area of 4,500sq/m. In 2014 and 2018, the company was chosen as the supplier of the year by VBG Truck Equipment – and this is where much of its work lies.  

Production Manager Magnus Strömberg says: “We want to invest in automation. We have automation cells that are 10 to 20 years old – but with the latest technology and systems, we can produce unmanned around the clock. This means much higher utilisation rates. Automating is also the best way to remain competitive against countries with lower labor costs. Previously, we had long set-up times and various other factors, we were left with long machine idle times and the inability to utilise our capacity. Now, we have truly unleashed our potential with the automation solution that helps us run production around the clock.”

Looking to the machine investment, Henrik Brodén, Scandinavian Sales Manager for Fastems says: “We streamline customer processes and the automation solutions we have today, both hardware and software-wise, provide safer and simpler processes. It’s important to notice that even for semi-automated systems that also include manual operations, there are options such as pallet systems and intelligent production control software that can increase utilisation rates.

Stenbergs, supplies CNC machines and tools. As a representative of OKUMA, Stenbergs can ensure high quality and the latest technology. The automation equipment from Fastems at KP Components consists of a so-called Flexible Pallet Container, an FPC 1500 which has a storage of 10 machining pallets. The FPC is installed directly against a machine’s APC and has an ergonomic loading station for clamping and detaching parts. Having all the pallets and fixtures available in the system ready for production and being able to buffer jobs for unmanned operation are some of the advantages.

Looking at the equipment at KP Components, Magnus Strömberg, the Production Manager, says: “We needed to replace an old faithful servant. It was time to switch out an OKUMA with a pallet system to something else. I was worried every morning, that the machine would break down and it would not hit our customers’ needs in respect of delivery times. That’s why I contacted Stenbergs – after all, we still are a satisfied OKUMA user. We discussed our concerns and in Stenberg’s showroom in Jönköping we saw the machine we needed.”

The customer requirements were fast delivery, integration capability for automation, and to take advantage of Fastems and Stenbergs software and mechanical components. The end goal was to reach higher productivity levels. The subcontractor sealed the deal and installed and ramped up in just three weeks. The machine purchased was an Okuma MA-600HII fully loaded horizontal machine with OKUMA Intelligent Technology. It weighs over 26 tons with a 12,000rpm 37kW spindle, an 171 tool ATC with tool ID. 

Working in synergy with the Fastems automation system, the chip basket is continually being filled and increased lights-out production is being achieved, as is more machining hours per day.

Laser installation and safety – it’ll be alright, won’t it?

Laser technology is commonly used for a wide range of tasks across industry and whilst some lasers are an integral part of ‘off the shelf’ standard machines, there are many applications where the solution is bespoke. In these instances, it is essential to consider all aspects of the final solution.

TLM Laser’s Andy Toms highlights the key areas which are sometimes overlooked by engineers not completely familiar with the use of laser technology.

The first step when seeking to purchase a laser source is ensuring that it is the right technology, Fibre, CO2, YAG etc. and the correct wavelength for the application. However, integration and operation must be properly planned comprehensively, taking into account factors such as the physical location, how and where the extraction system will operate and the safety aspects. Andy Toms explains: “All too often, installations are either completed by the end-user or together with an integrator who had little knowledge of the safe installation requirements. 

Systems need to conform to directives such as CE and UKCA, and additional guidance can be found from the classification scheme for lasers. This indicates the potential risk from exposure to the beam. Ranging from Class 1 to Class 4, with a total of 8 different levels of classification, the higher the class number, the greater risk posed by laser radiation. Failure to adhere to directives or regulatory requirements can have serious consequences. Company directors may find themselves facing legal action and any business insurance policy may be deemed void. If we compared the purchase of a laser system to that of a car, we expect the car to be complete with engine, powertrain, interior, and all safety technology in place. Only someone foolhardy would purchase the car with no safety features and implement these aspects themselves. 

Andy Toms continues: “There are so many points to consider to meet all required standards. By engaging with a qualified and experienced integrator at the earliest stages of a project, end-users will gain a comprehensive understanding of their application.”

As a business, TLM Laser has built up a portfolio of technologies which is supported by ancillary equipment ranging from laser safety eyewear to complete laser safe enclosures.

Unifabs enhances offering with new Amada machine

Nuneaton-based Unifabs has installed a brand new AMADA REGIUS high-speed CNC fibre laser profiling centre with load/unload automation and storage. The company is targeting 25% growth in 2022 and says the machine has already improved laser cutting speeds by 50% for certain parts. To further improve its ‘design to delivery’ offering, the company has also placed an order for a new AMADA HRB-ATC, the first mid-range press brake from AMADA that features automatic tool-change capability.

Founded in 2007, Unifabs is a £12 million turnover business with 125 staff that supplies precision sheet-metal parts to a customer base of blue-chip manufacturers from a single site with five factories that total 52,000sq/ft of manufacturing space. “Our goal is to be much more than just a supplier of sheet metal fabrications and parts. We want to be a manufacturing partner, supplying a start to finish service. Whether we’re supplying sheet metal components ‘just in time’ to a manufacturing line, or controlling the entire production process on a contract manufacturing basis, we operate as an extension of our customer’s business,” says Managing Director Tom James.

“We don’t specialise in one particular sector, but strong-performing industries right now include HVAC, catering equipment and construction. To ensure timely deliveries to our customers we continuously invest in the latest manufacturing technology. Even though we have an AMADA FOL-AJ 4kW fibre laser with AS LUL loading system and an AMADA EML-3610NT punch-laser combination with MP loading system, we were still outsourcing a lot of laser cutting,” explains Mr James.

To help improve lead times for its customers and regain control of its parts, Unifabs decided to invest in another laser cutter. “We looked at different models, but along with the increased processing speed we liked the automated setup features on the AMADA REGIUS, which we knew would help to reduce set-up/inspection time and maximise productivity,” he says.

Automatic inspection on the REGIUS utilises technology such as the AMADA i-Nozzle Checker to assess nozzle damage and circularity. If the nozzle requires changing, this will happen automatically via the machine’s 16-station nozzle changer, negating the need for subjective operator judgement. A further function of the i-Nozzle Checker is the automatic alignment of the nozzle centre if/when required.

Installed in November, the AMADA REGIUS is primarily processing mild steel, galvanised steel and zintec from 1 to 8mm thick. The machine features an AMADA ASLUL-3015 for the automatic loading and unloading of sheets and the storage of raw material, ensuring uninterrupted production runs. Typical batch sizes are in the region of 50 to 200. The REGIUS features AMADA’s new i-Process Monitoring system, which checks the wavelength of reflected light in real-time to provide a reliable indication of good or poor cuts. Automatic head collision recovery is a further function of i-Process Monitoring. 

The REGIUS CNC fibre laser profiling centre is not only the fastest in AMADA’s portfolio but the first to integrate several key technologies such as linear drives in all axes, the all-new laser integration system and variable beam control technology.

Bending is a core business function, which is why Unifabs has placed an order for a new AMADA HRB-ATC. Adding to the company’s existing seven AMADA CNC press brakes (HFE and HFP models), the HRB-ATC is the first with automatic tool change capability.

“We manufacture a lot of samples, prototypes and small batch runs to help get components ready for serial production. We have 10 people in our CAD team, so a lot of our work comes from the product development side of our business. However, these parts often have long set-up times, so we’re hoping that the new press brake’s ATC capability will have a big impact on throughput in this area. We’ll program a prototype part offline using AMADA software, send it to the new HRB-ATC and hopefully be folding metal within a few minutes,” explains Mr James.

Unmanned cylindrical grinding for small series production

MPS Micro Precision Systems AG (MPS) uses grinding for demanding high-precision components to IT02 tolerances. With a total of seven Studer grinding maachines, it has cylindrical grinding expertise in the medical and orthopaedics, science and optics sectors. Thanks to automation, series runs are flexibly produced unmanned 24/7, bringing prototypes to market faster. 

With more than 400 staff MPS was formed from RMB (Roulements Miniatures Bienne SA), a company formed in 1969 that developed components for the Apollo space mission. With 250 employees, Biel is the MPS Group’s largest site and has more than 140 turning, milling, grinding, polishing and eroding machines. 

Consistent investments in grinding machines

Michael Bazzan, the MPS Production Manager says: “With Studer grinding machines, we have high capacity for producing precision components. The grinding is matched to our varying size spectrum, which ranges from individual component production up to 25,000 pieces per year for some customers.” 

Three of the seven Studer machines are equipped with automatic loading. The focus is on the Studer S33 for recirculating ball screws and a Studer S21  flexible production cell (Flex Cell).

Didier Noirjean, Flex Cell Manager: “The cell was integrated into cylindrical grinding as a self-sufficient production unit to grind prototypes and new developments without intervening in production. With this cell, development to a finished part is quicker. The Studer S21 can be changed over quickly and configured for different parts.”

While the Flex Cell involves prototypes, series parts are machined on the other six Studers. These include recirculating ball screws from 0.8mm diameter. All components are developed and manufactured in-house. The larger screw spindles with gothic-arch thread are produced on an automated Studer S33.  M. Nercide says: “We are involved in R&D with these precision screw spindles. The expertise developed by MPS in the precise positioning of lens groups enables the company to offer powerful alignment systems for optical components such as zoom and laser beam systems.”

MPS Microsystems miniature recirculating ball screws are made from stainless steel and are positioned with double nuts that enable fine axial adjustment. The customised spindles guarantee smooth movement thanks to the high precision ground thread. 

The gothic-arch thread form is ground directly from solid hardened blanks. A macro was developed for these gothic-arch thread forms together with Studer. The grinding parameters can be adapted quickly to the respective screw spindles. 

Mr Weyermann, the Regional Manager at Fritz Studer AG adds: “The Studer S33 is a cylindrical machine with a turret wheel head. The wheel head has two external grinding wheels, one for thread profiling and one for external grinding.” 

To produce the medium-sized series cost-effectively, Humard developed a flexible handling system for automatic loading and unloading of workpieces in collaboration with MPS and Studer.

The Studer S33 requires 15 minutes to machine a screw spindle 8mm in diameter and 120mm in length. The thread is roughed and finished with the same grinding wheel. The grinding wheel is dressed repeatedly in the micron range throughout the grinding process. More than 1000 screw spindles of this size can thus be ground with one grinding wheel. The dressing process performs an important function during grinding. On one hand, the dimension and form are calibrated, and on the other hand, the cutting ability of the grinding wheel is defined. Both a diamond and a dressing roll are used for dressing. 

Finally, Manuel Nercide takes a look at the past: “Seven years ago we made between 2000 and 5000 spindles, today we produce 50,000 spindles a year. We have continually reduced our production costs, not least thanks to investing in modern grinding machines. Seven years ago our production was four times as expensive. From this perspective, investments in modern production equipment are crucial for ensuring long-term viability.”

Matsuura is an Oracle to 100% spindle uptime

Now approaching its eleventh year in business, Oracle Precision recently invested in an H Plus-300 machining centre from Matsuura. The MTD team visited the Rotherham subcontractor to find out why.

Shaun Palmer Commercial Director at Oracle Precision explains why the company invested in the machine: “Matsuura was certainly at the top of the list when we were selecting possible suitors. In addition to that, they held our hand throughout the technical review, they did the off-line programming and cycle time analysis which has a big bearing on our commercial position. The future for Oracle is to remain close to our suppliers that quite frankly, we need as much as our customers. We provide a solution to our customers problems. So, whether it’s a right now, short-term or long-term strategy for them – when we select machine tool supplier, it has to be a company that is in it for the long run.”

“With Covid, everyone has had to re-analyse where their own business is. We have seen customers present more order visibility than they may have done historically, as they have recognised the importance of the relationship. We have now become very selective over who our customer is and the level of support we provide. By investing in a machine in this climate, what more demonstration of an ongoing relationship can you present than that,” says Shaun. 

“By having this machine we have been able to service many more new and existing enquiries. We are serving more enquiries because our productivity and the visibility of our productivity has gone from sketchy, to 30 days to 40 days – and now we can focus right up to the following year where we can accommodate new customers as well as existing. We have survived Brexit and Covid, and we have found we were still turning work away during that period,” says Shaun Palmer Commercial Director at Oracle Precision. 

Alluding more specifically to the new Matsuura machine, Co-Director Mr Ryan Taylor: “We went for the H Plus-300 because of the pallet system, the swarf fall away, the efficiency and because most of all we already have Matsuura machinery, so we know the service and backup is something where they can hold our hand with a new piece of equipment. The pallet system is so important for us to create unmanned running. There are 15 pallets on the H Plus-300 and the idea is that we maximise the space per pallet to get as much product on as possible, giving us more unmanned hours and production. This is important to us as we are finding it harder to get the skills. Additionally, to be competitive we have to run around the clock and at weekends without a man at the machine.”

“When we were doing our investigation, horizontal cells were better for swarf evacuation and efficiency because the pallet system. So, one of the biggest reasons we have bought Matsuura machines is they have technology built into the machines, so if a tool breaks at night, the machine can quarantine thejob and fetch the next pallet and carry on with its workload. If it can’t rectify itself, it will send you an email so you can come in and rectify the problem.”

“The job that we have running on the H Plus-300 at the moment requires heavy cuts using 80mm diameter face mills and 40mm diameter porcupine cutters. We are hoping the H Plus-300 will mirror what we are achieving on the MX-330 10-pallet machine with near 100% spindle uptime,” concludes Ryan.

Life’s a beach with new CNC machine

As a heavy engineering specialist, LBBC Beechwood has invested in its first CNC machine, a Kiheung U1200N milling machine from Ward Hi-Tech. The West Yorkshire manufacturer purchased the machine to replace ageing equipment. MTDCNC visited to find out more.

When asked about the requirement for new investment, General Manager Mr Andy Quayle from LBBC Beechwood says: “We manufacture pressure vessels that can be used in autoclaves and decompression chambers, we also produce heavy machined parts used in the marine industry. Before this investment, we had an old boring machine that was 60 to 70 years old, and it did not comply with the latest health and safety regulations. We needed to invest, as some of our machines are quite old – so we decided to buy a CNC machine.”

Highlighting why the Pudsey based company looked at Ward Hi-Tech, Andy Quayle continues: “I had only heard about the machines about 18 months ago after I saw an article on LinkedIn. It planted something in my mind and when it came to starting to look at investing, I thought we could give Kiheung from Ward Hi-Tech an opportunity. 

Installed in 2021, the Kiheung U1200N has impressed LBBC Beechwood’s Kornel Pasztor. He says: “It was challenging to begin with because of the machine size. As we have two big doors at the front of the machine, we have really good visibility and if the cutting tool is cutting at the back of the part, we have the option to move the control panel to the back of the machine to maintain visibility. Additionally, as a universal milling machine, the head can be rotated in all angles and there is nothing that can’t be machined.”

Highlighting the components being machined, Andy continues: “The machine has a 4m bed and the materials we machine can range from aluminium through to inconel, and that is the beauty of this machine – it can cut a huge range of materials. The machine has also opened up new opportunities for us. In the past, we have subcontracted out some work, but as part of the LBBC Group of companies, we have been able to bring all of that work in-house and offer a much wider range for our customers. Customers that have worked with us in the past are now recognising that we have this capability.”

Looking at the power and stability of the 2-stepped gearbox 37kW spindle machine that can accept table loads up to 10 tonnes, Kornel says: “We are regularly cutting at 2 to 3mm depth with the feed rate of 1000 to 1500mm/min. The machine is really stable, and we are cutting beyond 0.5mm per tooth on steel and only getting 10 to 15% spindle load. The machine has 24 tools in the carousel and the Heidenhain iTNC 640 CNC controller is very easy-to-use.” 

Referring to Ward Hi-Tech, Andy says: “We explained that we were looking for a universal milling machine and Ward Hi-Tech put us in touch with another customer, we went to visit to see how they use their Kiheung. They showed us what it could do, and it helped to give us an informed decision.”

“It is our first CNC machine, so we needed handholding throughout the process. We had an old boring machine that we had to get out of the factory and Ward Hi-Tech were the only company that offered a complete package where they would project manage everything from sourcing a company to removing the old machine to doing the foundations and installation. They did everything and even provided a lot of training.”

FANUC delivers speed and flexibility for subcontractor

Founded in 1984, Apsley Precision Engineering Ltd was founded by Graham Aymes who had swiftly secured several defence contracts with customers that remain with the business today. To ensure the company remains competitive and flexible, the Salisbury-based subcontract manufacturer to the aerospace, defence and medical industries has recently invested in a ROBODrill D21LiB5 machining centre from FANUC.

Discussing why the company opted for the ROBODrill D21LiB5, Peter Aymes, the Managing Director of Apsley Precision Engineering says: “The ROBODrill has increased our machining capacity because it has a much higher spindle speed than our other machines and we have integrated a 5-axis unit with it as well. The ROBODrill is the fastest machine on our shop floor, it has a 24,000rpm spindle, through spindle coolant and a very fast chip to chip speed. With a BBT30 spindle, I was surprised by how powerful it is. We are machining tool steels, stainless steels, aluminium and any material that comes in front of us.”

“From the investments we have made over the last five years, we can supply 5-axis machined components, mill/turn components and anything else underneath. 18 months ago, we bought the ROBODrill because we were looking to shorten our cycle times. With a 24,000 rpm spindle and Nikken 5-axis unit, it has made a difference to our business. FANUC has an excellent reputation and their ROBODrill has been on the market for many years, and that is why we chose to go for this machine and go for an upgrade to the rest of the machines in our shop floor.”

With a BBT30 being smaller than the BBT40 spindle variant, Peter says: “The performance has surprised me. It can take really deep cuts just like you can on a BT40 machine – with the BBT30 spindle, it is extremely rigid. We run aluminium on the ROBODrill most of the time. However, it is perfectly suited to any other material that goes through the shop. So, today we are running tool steels and last week we were running 316 stainless on the machine. There is the assumption that BT30 spindles are not up to the job, but we have had no trouble at all when running all of those difficult materials on the ROBODrill.”

This rigidity is a credit to the BBT face and taper dual spindle contact system that demonstrates rigidity, stability and precision beyond that of standard BT spindle configurations. 

“We initially bought the machine as a 3-axis but then decided to add a 5-axis unit to it. That gives us the facility to complete components in a single operation as we have a fixed vice on one side of the bed and a 5-axis vice on the other side. This gives us incredible flexibility. I have taken parts from our other machines and put them straight onto the ROBODrill and it has proven to be extremely robust.”

Regarding the impressive speed of the ROBODrill, Peter continues: “The spindle runs 24,000rpm and it is the fastest spindle on our shop floor. This has enabled us to knock 40% off many of our cycle times. On the subject of speed, the tool changer is incredibly fast. It has a rotary carousel on there and that means the tool changes take just over one second, in some cases that alone has taken minutes of our cycle times.”

“The price of the machine is competitive, the cycle times are very short and that means that we get more value for our money. The return on investment for this machine has been much better than other machines that are comparable in the market, just because it is so much quicker. This means that we can get components off the machine faster and out to customers sooner than we would do otherwise. In terms of the size of the machine, it has a smaller footprint than a lot of comparable machine tools and this means that we can get more machines into the space that we have.”

“FANUC has been great at supporting us with this machine, the spares are readily available and the service engineers come out as soon as you need them. I’d recommend the FANUC ROBODrill because it is super fast, super accurate and excellent value for money,” concludes Peter.

Sliding-head is perfect choice for start-up subcontractor

Glenn Poleykett began his career in 2006 at his uncle’s firm, making components for darts on Cincom sliding-head and Miyano fixed-head centres from Citizen Machinery UK. He quickly realised that sliding-head lathes with driven tooling were capable of producing virtually any part 32mm diameter or smaller.

When Glenn started Stellar Precision Components 12 years later in Bishops Stortford, he remembered that lesson. He purchased two Cincoms, an L32-VIIILFV and an A20-VII. They have since been joined by an L20-VIIILFV.

Mr Poleykett said: “I worked at several subcontractors on various sliders, but I always regarded Citizen as the best. My opinion was reinforced when they introduced the LFV (low-frequency vibration) operating system software. It is programmable via G-codes to start and stop during any program, breaking what would normally be stringy swarf into smaller chips that cannot wrap around the tool or component.”

He witnessed LFV in action at Citizen’s technical centre in Bushey before he bought the first two lathes and described it as ‘incredible’. When machining short-chipping metals such as mild steel, 303 stainless and brass, it is not needed and the extremely short periods of air cutting slightly lengthen cutting cycles. 

However, when turning and drilling 304 or 316 stainless, aluminium, copper and plastics, he always turns on LFV. It greatly improves production output by not having to stop the lathe to clear the swarf and it allows the machine to run unattended. LFV oscillation of the tool by tens of microns not only breaks the swarf but also allows coolant to penetrate the cut more efficiently, reducing heat and prolonging tool life. Depth of cut may be increased substantially, even when processing tough materials.

Swapping between the two modes of LFV is simple according to Mr Poleykett. If a more vigorous chip-breaking action is required, for example when cutting plastics, and the other mode has been inserted in a program by Citizen’s Alkart CNC Wizard off-line part programming software, manual insertion of a single line of code at the start and finish is all that is necessary.

The most recent L20-VIIILFV delivered has the chip-breaking functionality on both the main and sub-spindle, whereas on earlier models it is applied to the main spindle only. The latest machine at Stellar was purchased for ventilator parts for the NHS. Funding through Citizen UK Finance and a six-month payment holiday smoothed the acquisition process at a difficult time.

Much of the throughput is destined for the aerospace, medical, electrical connector and pneumatics industries and batch size ranges from 10 to 40,000 pieces at the site that operates 24/7. Many of the components produced are of very high accuracy with a tolerance of ± 0.1mm down to ±5 microns.

Components up to the maximum bar size can be produced on both L-series lathes either when the guide bush is in place or guide bush-less mode, the latter being a standard feature of the machines. The L32 was installed with an optional extension kit that allows bar up to 38mm diameter to be accommodated, higher than the lathe’s nominal capacity of 32mm. This additional capability is regularly used and has allowed new business to be won.

XYZ enters the twin-spindle turning segment

On a recent visit to the Nuneaton showroom of XYZ Machine Tools, MTDCNC’s Paul and Gio take a closer look at the new twin-spindle SS 65 turning centre. 

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scussing the machine, MTD’s resident machine tool expert Paul Jones says: “It’s a machine that was launched at the back end of last year and there are models available in stock that engineers can come and see in Devon. The closest machine to it in terms of capacity, at the Nuneaton facility, is the CT65 LTY turning centre, which has Y-axis just like the twin-spindle machine.”

“XYZ has had a great start to the year, and this follows on from the success of 2021.” When asked why XYZ has brought a twin-spindle turning centre to the marketplace, Paul continues: “Just look at what happened with the UMC 5-axis machine. XYZ brought that into the country four years ago and last year they had the best year of sales with that machine. Year on year, as more companies recognise that XYZ is a 5-axis machine tool supplier, more people are buying into the company as a supplier of that product. The twin-spindle turning centre is the next venture for the turning centres of XYZ. They already have a single spindle with Y-axis, and they have been doing that type of machine for some time. They have tested the market, they have tested the technology and they have customers with multiple turning centres. So, the next step is the twin spindle.”

“What does it mean for XYZ users? It means that customers can now machine parts in a single operation. It means that a raw billet can go on to the machine and a finished part comes off.” Looking closer at the specification of the machine, Paul adds: “The machine has the Siemens touchscreen CNC control, a 65mm bar capacity, a 100mm Y-axis on the machine with powerful spindle motors, 4000rpm main spindle with 5000rpm on the sub-spindle for finishing parts. Additionally, the machine has optional extras that include the swarf conveyor, part catchers, tool setters – all of these things are available on front and back spindle with this model.”

“Some key areas that stand out are the control system with the Siemens Shopturn that allows manufacturers to program at the machine very easily, reducing the learning curve. The controller can be used to fully assist the operator – and don’t forget that it’s a big thing as XYZ have sold machines in the past based upon their control technology and ease-of-use. Engineers buy into this, and operators want the ease of use – they want the transition from lower forms of technology to new modern-day machinery to be as simple as possible. That is what XYZ can do with this new twin-spindle machine.”

“There are currently machines in stock in Devon at the XYZ headquarters. There will also be a machine at MACH 2022, and of course, people can see the machine on the XYZ website and via MTD videos. Where this machine will be good for XYZ is where they may have lost business in the past with businesses that wanted twin spindle technology that XYZ could not provide. Now they can. So, engineers can buy their VMCs, the 5-axis machines, bed lathes, oil country machines and now multi-axis turning centres for machining in one hit.

The XYZ SS 65 features a 16.5kW spindle motor with 65mm bar capacity and 200mm diameter chuck as standard and an 11kW 5000rpm sub-spindle with a 52mm bore and 150mm chuck. The German-built Sauter 12-position turret has live tooling at every station and contouring is facilitated by the C-axis on both spindles.

Gearwheel manufacturing in a 34-second cycle

Minimising production times to ensure competitiveness is one of the most important challenges in the automotive industry – Henry Ford recognised this over a century ago. After decades of optimisation, it is difficult to reduce machining times further while maintaining the same level of quality. Nevertheless, Volkswagen (VW), near the German town of Kassel, has managed to achieve this in its gearbox production facility using Kapp Niles gear grinding machines that are available in the UK from the Engineering Technology Group (ETG).

The VW plant in Baunatal is one of the larger German locations of the enterprise with a workforce of about 17,000. Its production focuses mainly on gearboxes in ten different series. Gearing centres from Kapp Niles are being deployed on 50% of the manufacturing lines. Kapp Niles is primarily known as a specialist for hob grinding with dressable tools.

880 gearboxes per day

Kapp Niles machines are also applied in the production of the DL382 dual-clutch gearbox for Audi. A total of sixteen gearings is required to shift the seven gears with this type of gearbox – ten ground and six honed. The production unit runs 24 hours a day, 5 to 6 days per week. VW strives to achieve an EPEI (every part every interval) value of 1 day in the production unit. This means that all components can be produced on each day for the aforementioned gearbox. This streamlined production requires seamless processes and a high degree of flexibility. Technical clerk, Christian Hahn, is in charge of the production process of the DL382 dual-clutch gearbox. He describes the production process: “We have five gearing centres from Kapp Niles in the wheel production unit and two more in the shaft production unit. To achieve an EPEI value of 1 day, we change over the machine in the wheel production unit twice a day.”

The challenge with flexible production is the short cycle times. With an output of 880 gearboxes per day, one machine in wheel production must produce 1,760 parts per day. Including all set-up times and failures, yielding a line cycle time of 34 seconds. An average line cycle time is about 39 to 40 seconds. Bernd Kümpel, application technician at Kapp Niles, analyses these figures: “Saving 5 to 6 seconds per cycle does not sound like a lot at first, but together it can be a 15% reduction. If I consider that at least 40% of segments cannot be influenced, I have to reduce the actual process time by 30 to 40%. Seen in this way, 34 seconds a real challenge.”

Saving precious seconds during changeover

A total of seven Kapp Niles machines are being deployed at VW. The machines include three KX 100 DYNAMIC, two KX 260 TWIN in wheel production and two KX 160 TWIN in shaft production. Christian Hahn and Bernd Kümpel agreed from the very beginning that the desired cycle time could only be achieved with a combination of several measures. To minimise daily set-ups, Christian Hahn makes sure that the wheels to be produced on one machine have boreholes of the same size. Thus, he has to change over the machine, but not the clamping tools. The remaining set-up time is minimised by the set-up concept of the KX 100 DYNAMIC. For one machine, he needs just 20 to 25 minutes. “The semi-automatic set-up makes the   KX 100 DYNAMIC extremely user-friendly,” says Bernd Kümpel, describing the process. 

Additional visual aid is available in the form of a menu guide and an easy-to-understand cycle on the machine controller. By completing the step-by-step process and the acknowledgement screen, the operator ensures that no work steps are executed incorrectly and high-cost failures are prevented. 

The tools are dressed using full profile rolls, allowing all threads of the cylindrical worm to be approached and moulded simultaneously. Thus, with a 5-pass full profile roll, the dressing time can be reduced by more than half without compromising on quality.

The integrated measurement system is another important time-saver. Christian Hahn explains the advantage: “After each changeover, quality measurement has to be made outside the machine. We continue to require this, but I can already check the basic, quality-related parameters with the integrated measurement sensor in the machine itself. It saves a lot of time  as we can start production before the results of the external measurement are available.” The integrated measurement system of the Kapp Niles machines accelerates the restart process considerably. The external measurement merely checks more teeth and generates the measurement report to monitor the gear.

Open for new machine tool technology

The search for optimisation potential also includes the actual grinding process. Cubitron™ II machine tools by 3M™ show a highly promising approach, with geometrically specific triangular-shaped cutter heads, compared to conventionally dressable grinding wheels. 

For this purpose, Kapp Niles provided relevant preparatory work with a large number of grinding tests in-house to be able to use the benefits of this machine tool with the DL382 components. Bernd Kümpel adds: “With CII, you can remove a considerable amount of shavings without any thermal damage to the component. This way, we reduce consumption time by 30% compared to other grinders.”

Saving space and money

Production is characterised by belt chaining that goes through the entire hall. Available space is limited, hence, the highly compact KX 100 DYNAMIC machines are the preferred choice. This machine type has two separate rotatable mounted columns, each with vertically movable pick-up axes with one workpiece spindle. While a workpiece is being machined, the other pick-up axis places the machined workpiece and loads a non-machined part onto the workpiece spindle. The workpiece is aligned outside the work area. This allows the workpiece spindle, already accelerated to machining speed, to be swivelled in the work area, keeping non-production times to a minimum.

A transfer unit does the loading and unloading from the conveyor belt. Bernd Kümpel says: “We usually move with the belt directly below the machine. However, this was not possible here. With the transfer unit, we compensate for height and distance from the belt to the machine. An integrated automation solution would have been significantly more expensive, at about 25% of the priceof the machine,” addsBernd Kümpel. “A simple transfer unit costs less than 10% of the machine price.”

Planned success

Christian Hahn says: “Throughout the process, we were convinced by the machine concept and managed to overcome any obstacles together. The cycle time was a critical aspect. But, we did it.” The commissioning included the machine capability analysis, where 100 components of each type are produced and measured 100%.

Apart from the cycle time, other difficulties were overcome in the shaft production and Christian Hahn describes it as follows: “The shafts are hollow and comparatively unstable. This called for a special clamping technique and a machine that can absorb the unavoidable vibration in the grinding process. The KX 160 TWIN can do this due to its solid design and construction which in turn helps to achieve better grinding quality.”

See what the world’s largest machines can achieve at MACH

On Stand 110 in Hall 17 at MACH, McDowell Machining Technologies will be demonstrating why it is the premiere machine tool solution supplier for the heavy manufacturing sectors. From the 4th to the 8th of April, McDowell will be introducing the colossal machining technology available from WaldrichSiegen part of the globally renowned HerkulesGroup, as well as their industry leading solutions from Niles-Simmons. 

In early 2020, WaldrichSiegen investigated the UK market to find a technical partner rather than historical sales agents that have come before. After speaking to several machine tool references throughout Europe to gain insight into the UK heavy and large capacity machine market to ascertain who was active in this field, the answers kept coming back the same – McDowell Machining Technologies. This company has become known for prioritising the large and heavy machine tool sector over commodity machine sales and are actively a technical project sales-driven company. 

Commenting upon the relationship, McDowell Machining Technologies Managing Director, Mr Stuart McDowell says: “It was very well received being contacted by WaldrichSiegen, since entering the large machine tool market more than 15 years ago, our business has gained vast experience and exposure with many OEMs. It has always been very clear who the top performers are, who has the best product offerings and who has the stature to deliver on large projects. With this knowledge, it was very easy for me to encourage the advances of WaldrichSiegen and enter into a long term strategic partnership. We have formed excellent working relations over the past couple of years and are very excited about what the future holds.”

McDowell Machining Technologies will support its partners with its ever-expanding team that currently operates with 16 service and applications engineers that are supplemented further by reliability and project engineers. This resource was attractive to WaldrichSiegen, but more important is the collective experience and exposure to heavy hydrostatic machines and the environment they operate in. At MACH, this expertise will be on-hand for show visitors to discuss their large machining projects. 

Commenting upon the new relationship, Dr. Thorsten Mehlhorn, President and CSO of HerkulesGroup global sales said: “In the course of our further strategic alignment, the UK market is an important milestone in our growth. We were looking for a technically experienced partner who is experienced in the large and heavy machine tool sector. We are very excited about our future strategic partnership with  McDowell Machining Technologies. Our focus lies on target-oriented and innovative consulting by technically experienced personnel. We are looking forward to continuing a professional and cooperative partnership.”

Reinforcing this opinion, Marco Tannert, the President and COO WaldrichSiegen states: “With McDowell Machining Technologies, we found a professional partner in the UK that is a technical expert for heavy machine tool projects and has significant experience in maintenance and repair works for all kinds of large machine tools. Together, we will be able to take our service to UK customers to a new level.”

Introducing the WaldrichSiegen brand to MACH for the first time, McDowell Machining Technologies will be highlighting the range of machines that encompass everything from milling, turning, vertical turning, turn/mill centres, grinding and boring machines. The WaldrichSiegen series of portal milling machines will be introduced at MACH and with a fixed or movable cross rail, the ProfiMill is available with a clearance between the columns from 3m to 14m with a clearance from the table or floor plate to the spindle nose of 2m to 12m with table width from 2.5m to 8m with a length of 5m. If the dimensions appear incomprehensible, the exhaustive choice of milling units all manufactured by WaldrichSiegen will certainly resonate with engineers. 

Complementing the ProfiMill is the ProfiTurnV vertical lathe that excels in precision, efficiency and reliability. The ProfiTurnV stands out from its competitors due to its uncompromising performance and precision in roughing, semi-finishing or finishing. The ability to integrate a variety of technologies allows for the highly flexible machining of complex workpieces. The fully hydrostatic design in all main axes guarantees the ultimate in cutting performance and accuracy whilst guaranteeing no wear to critical surfaces. Facilitating parts up to 500 tonnes with maximum turning dimensions of 13m diameter by 11m height, the ProfiTurn V rotary table is available with power of 300kW with 560,000Nm torque and Y-axis. Ram (Z-axis) travel of up to 4m is available with numerous ram sections and attachments selected to best suit the application.  

Across both ProfiMill & ProfiTurnV platforms, the standard W-axis cross rail is integrated due to its dynamic capabilities. This axis optimises the axis positioning to suit the individual workpiece and directly influence cutting performance. The fully equipped axis tracks all machine geometry and doesn’t influence workpiece datums when moved for instance to a second home position to change a head or a tool. Not only are these operations fast, but also do not compromise quality. Furthermore, the standard ‘no counterbalance’ system also has a huge influence on machine reliability and performance. By removing the counterbalance, it effectively removes a part of the machine that requires intensive maintenance – ropes, chains, pulleys, cylinders and valves. 

There are further benefits to the machine performance, the counterbalance does in effect apply the same force in the opposite direction to what gravity creates. By equalling this force, there is a load on the positioning system of the machines that needs to be overcome when moving. This load creates wear on the ball screws, heat on the motors and drives, and makes fine positioning more challenging. By removing these factors, the machine is much more reliable and accurate. The standard C-axis design located within the ram brings added capability to all the milling heads by enabling them to move continuously through the Z-axis. For heavy workpieces that require contouring with complex tool paths, this additional feature means the machines do not have to dramatically move the workpiece (in C&Y) and instead move over the part in all axes without limiting access whilst ensuring stability.

WaldrichSiegen is acclaimed for producing the world’s largest horizontal turning centre with a 7m swing and turning length of 35m, capable of accommodating parts up to 350 tonnes the WaldrichSiegen range of ProfiTurn H (horizontal), and ProfiTurn M mill/turn centres available from McDowell Machining Technologies set the standard for heavy turning. Designed for maximum performance, the ProfiTurn H can also be specified as a turn/mill centre to reduce set-ups and improve productivity and flexibility for customers. The ProfiTurn H provides the highest level of accuracy, reliability and performance that enables high quality and economic machining of complex workpieces. The rugged design demonstrates maximum stiffness of the overall machine structure, and the range is equipped with hydrostatic guideways in all linear axes to provide high, wear-free operation along with excellent damping characteristics. From a power perspective, the H series delivers up to 500kW of power with 400,000Nm of torque. Despite the ability to support oversize and heavy workpieces, the H Series retains a concentricity of up to 5 microns – truly amazing for components of such size.  

For more complicated components that demand milling capacity, the ProfiTurn M series has been designed specifically for the complete machining of complex workpieces. Turning and milling units, as well as boring and grinding units can be attached to the master head interface located on the milling tower. The result is the highest efficiency, as all stages of the machining process are performed on a single machine, eliminating multiple set-ups that are both elaborate and costly. Whether turbine or generator rotors or heavy forged parts – the ProfiTurn M has been developed for the precise and efficient machining of demanding workpieces with a diameter up to 4.5m, with a maximum workpiece weight from 20 and 250 tonnes. 

Continuing the impressive machine portfolio is the globally renowned Union horizontal borers. A selection of floor, planer, table and compact boring machines are offered with a seemingly endless list of options to tailor the machines to the customer requirements. The Union machines guarantee the efficient machining of workpieces with a length up to 40m and a height up to 10m with a weight of up to 250 tonnes. 

From the cost-effective solution with universal applicability up to high-end equipped boring machines for XXL workpieces, the modular structure of the P/PR series, the double hydrostatic guidance, and the dynamically controlled hydrostatic system allows both to have roughing and high-precision machining. 

That being said, not everything in the WaldrichSiegen range from McDowell Machining Technologies has unfathomably large dimensions, as the TM125 table-type compact boring mill demonstrates. This innovative foundation-free compact boring mill for the effective and cost-efficient machining of workpieces up to 10 tonnes with a set-up area of up to 2.5m by 2m by 1.6m. It combines the advantages of a table-type boring mill with those of a compact machining centre. Despite the size of the TM125 and the similarly sized KG precision series of boring mills; precision, stability and repeatability is assured. The KG range demonstrates positional accuracy of less than 8microns. 

Whilst WaldrichSiegen provides ideal solutions for heavy manufacturing sectors such as the offshore and wind energy, power generation, mining, engine manufacturers and the steel making industries, the smaller, agile Niles-Simmons brand of machines will also be presented at MACH with a host of automotive and aerospace demonstration components that will highlight the flexibility, precision and scale of what is possible with these incredible machines. 

The Niles-Simmons brand is the true epitome of high-quality bespoke manufacturing solutions with unparalleled precision and productivity. As the brand of choice for many of the world’s leading OEM manufacturers, the Niles-Simmons portfolio includes everything from turning and turn/mill centres, vertical turning centres and 3 to 5-axis machining centres that can all be tailored to the exacting demands of the end-users. The MC-series of turn/mill machines range from the N20 MC to the N60 MC with a turning diameter from 650 to 1500mm and a maximum turning length up to 7.5m. These machines can be configured as single or multi-slide machines and thanks to the modular building-block system, a variety of machining units can be added to offer the utmost flexibility. Adding value to these machines, Niles-Simmons can incorporate gear hobbing, skiving, grinding, deep hole drilling, ID machining with a boring quill, 5-axis milling, crankshaft milling units, up to three steady rest slides and much more.

Alongside these incredible systems, McDowell Machining Technologies will present a selection of vertical turning centres with the RQ and RQQ variants offering single or twin turning tools that can engage with the workpiece simultaneously to improve productivity whilst the RMC range is equipped with a turn/mill unit for the machining of rotationally symmetric workpieces up to 1.6m diameter. These machines would be of a typical interest for the highly efficient machining or railway wheels or large disk type parts. For more information on the product offerings and solutions available from McDowell Machining Technologies and their partners WaldrichSiegen and Niles-Simmons, visit them at MACH 2022 on stand 17-110.

Partnership and collaboration will be crucial to aerospace’s post-Covid recovery

For decades, aerospace has been an industry characterised by growth. There have been crises over the years, but never one so deep and heavy as Covid-19. Now that the markets have returned to levels of growth last seen in 2006, how can aerospace manufacturers get back on track? The answer lies in more sustainable manufacturing. Here, Sébastien Jaeger, Industry Solution Manager – Aerospace for cutting tools Sandvik Coromant, explains how collaboration will play a vital role in the recuperation of the industry.

The aerospace industry had been growing for 14 years when the pandemic struck. There’s no doubt that the future of aerospace has been immensely affected by the pandemic. There has been exponentially reduced business and holiday travel, while airlines have had to adjust to substantially lower levels of profitability. 

It isn’t all bad news. The aerospace sector has seen some improvement in the first half of 2021; but success is tied to several factors like vaccinations, the global economic outlook, business and holiday travel recovery also having an influence. Projections estimate the industry will be back to pre-crisis levels within the next two to three years. The speed of this recovery will vary in different countries and regions. Nevertheless, over the long-term, the number of new aeroplanes could still decrease by 25% by 2040. 

Another big change, from an engineering perspective, is that aeroplanes will be single aisled rather than twin aisled. They will also be required to have a longer flying range. Engines and frames are closely connected. One doesn’t go without the other but with engines, we can say the focus is on sustainability. This means the reduction of weight, noise and emissions and higher efficiency with less consumption. These single aisled craft must satisfy a wide range of uses, without increasing the size or quantity of engines. 

There are different ways of approaching these design challenges. One is to find alternative fuels using existing engine tanks, such as synthetic fuel, biofuel or hydrogen. Then you have new engine architecture with large manufacturers presenting new types of engines. Then we have alternative forms of engines that are electrified, battery-driven or electromagnetic, or hybrid engines where current engines are assisted by electric power motors. 

Challenging materials 

If we look at the automotive industry, it is already making progress with new electrified and hybrid systems. Aerospace OEMs are still working on these systems and many developments are not expected to find widespread use before 2035. With smaller aircraft, these technologies could appear earlier. 

Reductions in noise, weight and emissions will affect how these electric systems perform, but there are challenges. If there are issues in an electric vehicle (EV), it can stop at the side of the road — that’s not an option 10,000 feet up in the air. What’s more, batteries are heavy when designers want planes that are lighter to travel longer distances. For an aircraft fuselage, OEMs are going in two different directions. On the one hand, we are seeing increased use of aluminium, although aircraft components require new types of aluminium with greater strength, fatigue resistance and other attributes. This approach adheres to traditional aircraft designs where you have a big tube with wings and an engine. 

Another approach is to explore other shapes of aircraft like delta shape, blended wing body and strut-braced wing or where the engine is more integrated into the fuselage. Here, engineers will more likely turn to composite, or composite-ceramic combinations and mixed materials. Whether these designs become popular remains to be seen. For now, we can be sure that more aluminium will be used and also heat resistant super alloys (HRSAs). HRSAs are typically used for aircraft parts that face extreme performance demands. However, even the best aircraft component manufacturers can be inexperienced in manufacturing these tougher materials. 

Component solutions

Sandvik Coromant offers component solutions in response to the growing pressure on machinists to multi-task. Rather than focus on one machine, today’s engineers can operate four or five machines at a time. But, what do we mean by a component solution? It refers to taking a more holistic perspective, not just about the tools but also about assisting with the complete process.  

That was the case when a Sandvik Coromant aerospace customer was challenged when machining HRSA. The existing approach required multiple machine tools with poor chip control and long cycle times. There were issues with inconsistent tool life and unreliable processes, and the operation often required full-time monitoring by an operator. For high-value projects like these, the solution consists of several stages. They include looking at the machine requirements, time studies to examine the cost-per-component and analysing production methods at the run-off related both to Methods-Time Measurement (MTM) and end-user processes. It also includes CAM programming and project management. 

These analyses revealed that we needed to change the programming strategy to solve chip breaking problems. In combination with the tool, Sandvik Coromant’s specialists developed a new strategy with dynamic drive curves to control chip breaking. We called this new approach scoop turning and now have a patent for it. 

Scoop turning results in very good savings for the customer. Besides great chip control, and 80% cycle time reduction and double tool life were achieved. It reduced machines from four to one, reducing the need for multi-tasking with more secure machining processes and green light production. 

This shows how a more holistic approach can benefit the bottom line. The software also plays a vital role, such as CoroPlus® Tool Guide, which is part of Sandvik Coromant’s digital portfolio. Customers can make crucial decisions on the choice of tool and cutting parameters before production.   

More sustainable turning

Aerospace manufacturers are taking different approaches to tackle sustainability. Nevertheless, Sandvik found it is possible to develop a bespoke solution for one customer that has since benefitted entire industries. To help the customer perform better turning on HRSAs, Sandvik Coromant’s response was to develop the S205 grade. The insert has second-generation Inveio® coating for high wear resistance, while post-treatment technology strengthens the insert. The material has an Inveio® layer with tightly packed, uni-directional crystals which create a strong protective barrier around the insert. 

The grade is well-suited for machining components such as aircraft engine turbine discs, rings and shafts. Our customers have reported 30 to 50% higher cutting speeds with S205 compared with competing HRSA turning grades. S205 has since benefitted several manufacturers in aerospace and other industries. These results were achieved with a holistic approach, specifically with Sandvik Coromant’s PrimeTurningTM ethos that allows all-directional turning for maximised productivity. 

The PrimeTurningTM methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This prioritises metal removal rates for faster production. Aerospace may be facing one of its biggest crises yet, but there is light behind the clouds. Sandvik Coromant continues to support aerospace OEMs to support their post-pandemic recovery, marrying sustainability with better tools and optimised cutting parameters with a holistic approach to tooling.

Billet machining cuts time to market for Techni

As a leader in the design and production of cast mount and drive solutions, Techni Ltd products are used across many industry sectors. If you need a mobile tyre fitter, utility vehicle or are receiving chilled supermarket deliveries, the compressors would probably have been made with a Techni systems mount kit.

Compressor brackets are typically machined from SG iron castings as normal batch sizes make this the most cost-effective method. However, the significant increase in home deliveries due to Covid has demanded a faster turnaround and lower volumes with diverse configurations. This increasing demand for lower volume fast turnaround posed issues for the casting method of production, which for a new product could take as long as six months to get to market. 

“To compete, we needed to review our methods to reduce lead times by as much as possible and billet machining was the logical step. This is a new road for us to go down and it makes shorter runs, even one-offs viable as we are eliminating costs, such as fixture design and manufacture. All we need now is a vice and good tooling,” says Ali Kerr, Techni’s Manufacturing Engineer. To help with the workholding, tooling and methodology, Techni turned to Ceratizit Technical Sales Engineer Derrick Jones.    

The first stage is to 3D scan the van engine bay to be fitted with the system. OE CAD is then required to allow the design engineers to design the mount brackets. Billet machining eliminates the need for the draft angles or runners required for castings, which makes parts much simpler to design. Typically, brackets can be produced from a 270 by 90 by 180mm billet. To grip these, a WNT ZSG 4 Centric vice, mounted on a WNT Zero Point MNG Riser Console is used to grip on as little as 3mm of material without any pre-preparation of the billet. 

By mounting the vice on the MNG Riser Console, access to five sides of the billet is straightforward and helps reduce tool overhang, allowing increased cutting parameters. In the case of Techni, the 3mm of material is left in situ after machining rather than removing it with a second operation. With the billet gripped, up to 90% of the machining is carried out using a WNT CircularLine end mill, which provides up to 80% of the hardness of natural diamond to protect from damage caused by built-up edges. At Techni, these cutters are being run at 450m/min with 0.2mm/tooth feed on the 14mm diameter five flute cutter with a step over up to 20%. Out of the total 1-hour 45-minute cycle, the Circularline cutter is engaged for about 95 minutes and after an initial batch of 50 brackets, it still delivers the surface finish results required.

“The help we have received from Ceratizit has been invaluable, and while some elements of billet machining are greater than casting, for example, a casting may cost as little as £20, compared to £80 for a billet of aluminium, machining time for a casting is around 20 minutes, not 105 minutes,” says Ali Kerr. “Even with these increased numbers the argument for billet machining is easily won, simply with the reduced time to market, initial cost to create a casting and typically around £2,000 – £10,000 for fixturing. We can now deliver finish machined parts to customers within a week if required, this would compare to four months for a new cast product. This gives us a valuable competitive edge with new customers or projects. In future, with batch quantities up to 300, billet machining will offer a significant advantage.”  

By working with Ceratizit, Techni has developed a process to respond to customer demand in a timely and cost-effective way. “The ZSG 4 vice and MNG zero-point system along with the Circularline DLC cutter are popular standard elements of our product portfolio and provide an excellent example of how a highly effective solution to a machining problem can be created with minimum investment or disruption,” says Ceratizit Technical Sales Engineer, Derrick Jones.

Vargus threading line goes supersonic

As a manufacturer and supplier of precision threading, grooving, turning and hand deburring tools, Vargus Tooling UK Ltd has now launched its new series of MACH Supersonic Threading products. Developed for improved productivity when threading, the new MACH Supersonic Threading range is a new innovation. 

The new series incorporates a complete range of thread turning tools and thread milling products. The patent-pending turning range has been introduced with a range of MACH TT external inserts and corresponding MACH TT toolholders. The MACH TT external turning inserts are available with both a 55 and 60-degree partial profile, ISO metric, American UN, Whitworth for BSW and BSP, BSPT, NPT, NPTF, Round and Trapez, UNJ, MJ, API Round and Metric Buttress. 

This range of inserts caters for the complete threading spectrum and is capable of producing threads twice as fast as competitor products due to several innovations. Each of the respective thread geometries incorporates an improved rake with a reinforced geometry that creates a strong insert design with a high resistance that permits cutting at higher speeds and reduces the number of passes required. 

Adding to this geometry is Vargus new VK8 insert grades that combine an AlTiN and TiN PVD coating to give durability and performance on a complete range of materials from steel and stainless, cast iron and nonferrous materials through to heat resistant alloys and hardened steels. The surface treatment and profile design reinforce the strength of the cutting edge whilst providing a smooth surface finish and superior thread profile. This reduces the number of passes required to decrease machining times and extend tool life whilst delivering unsurpassed thread quality. 

Every thread designation is available with a vast array of dimensions and thread pitches to meet all of the threading demands of the industry. Working in complete synergy with the indexable triangular inserts is the respective toolholder with the Vargus dovetailed clamping system that is rigid for high load machining. The toolholders are available without or with through coolant facility that improves chip breaking and prolongs the life of the tool by delivering high-pressure coolant directly to the cutting edge with both a top and bottom coolant outlet channel. The tool shanks are available with a 12 or 16mm width and depth for application on Swiss-type sliding head turning centres with 20, 25 and 32mm toolholders also available for application on a complete range of turning centres. Additionally, the toolholders are available in lengths from 84.5mm to 170mm to suit specific machine tools. 

Complementing the thread turning range of MACH products from Vargus is the new MACH TM thread milling range. Like the thread turning range, the MACH TM thread milling line is available in a complete range of thread geometries to cater for the demands of any machine shop. The solid carbide high-performance threadmills incorporate an improved cutting-edge design with a reinforced geometry to allow cutting under high loads with maximum efficiency. Complementing this design is a large core diameter that increases the stability and strength of the MACH TM series to enable higher speed and feed rates. Further enhancing the ability to cut at high feed rates is a design feature that includes a fourth flute that further improves cutting performance and evacuates the swarf at speed. Assisting this tool design in removing chips from the cutting area is a through coolant facility that flushes the swarf from the cutting edge. 

For prolonged machining performance, Vargus has introduced its new VH4 high wear resistance TiCN PVD coating technology to its new MACH TM series. This surface treatment enables the new thread mills to improve surface finishes whilst prolonging tool life by reinforcing the cutting edge. Creating further stability and rigidity for the cutting edge, Vargus has optimised the flute length of the MACH TM series – taking performance and tool life further. 

The helical flute tools are available in a complete range of thread sizes and pitches to suit the end user’s requirements. For example, the ISO Metric thread mills are available from M3 to M20 with both coarse and fine pitch options with tool diameters from 3 to 16mm and lengths from 28 to 102mm with four or five flutes depending upon the selected tool diameter. This diverse range of sizes is also available in the NPT, BSP and American UN designations with thread mill sizes ranging from 1/8 inch to 2 inch depending upon the specified thread geometry. Like the MACH TT thread turning series, the MACH TM line is a performance range that is capable of cutting materials from steel and stainless through to cast-iron non-ferrous materials and heat  resistant alloys.

Buying into ‘Infinite Possibilities’

Founded in 2016, HSM Components in Deeside, has identified ‘infinite possibilities’ since working with Quickgrind. Specialising in bespoke components, the company recently started working with Quickgrind on a new automotive project. 

The Flintshire manufacturer recently won an order to manufacture big bore engine blocks on Suzuki Hayabusa motorcycle engines for a motorsport customer. With specialist tooling needed to machine the blocks from aluminium 6082 billets, HSM had an issue with acquiring bespoke cutting tools and completing the project to the rapid lead times required. Luckily, HSM discussed the project with Mark Aspinall from Quickgrind who introduced the ‘Infinite Possibilities’ concept and the company’s ability to quickly produce special tools. 

The challenge for HSM was the machining of a water jacket slot around the cylinder bores as well as the machining of a pocket at the end of the cylinder head for the cam chain. The water jacket slot has a width of 6mm and a depth of 52mm. The pocket for the cam chain goes all the way through the engine block and has a corner radius of 4mm. It also has tapered walls, so can only be machined from one side to a depth of 88mm. HSM needed end mills that would demonstrate stability and performance – the Quickgrind Caiman was the solution. Commenting upon the application, Quickgrind’s Mark Aspinall recalls: “The Managing Director at HSM, Mr Steve Rigby knew exactly what he wanted to achieve and this had to be adhered to by a particular timeline. When I explained the ‘Infinite Possibilities’ philosophy, Steve bought into our ability to make bespoke tools in a fast lead time that are produced here in the UK. Based upon the parameters of the blocks and the features, we introduced the 3-flute solid carbide Caiman end mill with an aluminium geometry specific to the project.”

HSM Components Managing Director Steve Rigby says: “This customer is a specialist race engine builder that we already manufacture several products for. They brought us the small batches of 5-off cylinder blocks to meet the requirements of its global customer base. Previously the company had been using overseas manufacturers with a minimum batch quantity of 10-off and a longer lead time. By working with HSM, this customer can reduce their order volume, inventory and  lead times.”

“Each block requires 10 hours of machining with four setups. To support this, we had to manufacture special fixtures and use bespoke tooling from Quickgrind. We use several cutting tool suppliers, but none could either manufacture or supply off the shelf tools to meet our needs.”

Quickgrind supplied a 5.5mm diameter Caiman square-end tool with a 10mm flute length and necked 57mm for clearance. With an overall length of 108mm on a 6mm shank, the geometry maximises the rigidity of the tool, demonstrates exceptional swarf removal and provides outstanding surface finishes in the water jacket channels. 

The next feature that required machining on the engine block was a cam chain pocket with a tapered wall at the end of each block. To facilitate this, Quickgrind supplied a Caiman 3-flute end mill with an aluminium geometry and corner radius. The 7.5mm diameter end mill with a 2mm radius has a 10mm flute length necked back 94mm to provide reach into the deep pockets. With an overall length of 150mm and an 8mm shank, the short flute length demonstrates exceptional rigidity. 

“What HSM needed was high-performance aluminium tools with a geometry, flute length and reach that would meet its exact requirements – all within an extremely fast turnaround time. HSM’s existing suppliers could not manufacture the bespoke tooling to the required lead times. Our ‘Infinite Possibilities’ enables us to produce specialist cutting tools on very short lead times, which is ideal for customers that have to meet stringent project deadlines,” continues Mark Aspinall. 

Machined on a Hurco VMX42 and programmed with hyperMILL CAM software, the addition of new cutting tools has minimised the cycle time. Concluding on the project, Steve Rigby says: “We initially completed three engine blocks as a trial to improve quality and lead times, we are now working on another batch of five engine blocks.”

Giving the auto industry a spark

With increasing public awareness of global warming, together with a pressing concern to create and maintain a clean environment, legislation is evolving worldwide in all walks of life. In the automotive industry there is a drive to force automotive manufacturers to decrease CO2 emissions. 

As well as improving fuel consumption, downsizing engines and making vehicles lighter, manufacturers must turn to new technologies in order to cope with these emission limitations. A rapid increase in battery electric vehicle (BEV) development, manufacture and implementation shows that electric vehicles are not only the future but are, in fact, the present. The automotive industry is on the brink of colossal changes and soon our perception of cars and transportation may alter completely.

ISCAR, a company with many years of experience in the production of metal cutting tools, offers insightful cutting-edge solutions for the new BEV Industry. As a leader in providing productive and cost-effective machining solutions, ISCAR strives to stay up to date with all the new trends and technologies with the aim of creating a brighter, greener future for us all.

The following is a list of some of the common component machining processes in the BEV industry and some of the leading possible machining solutions and recommendations for each part.

Stator housing machining

One of the most notable trends of the electric vehicle powertrain is its simplicity. There are far fewer moving parts compared to the traditional internal combustion engine (ICE), therefore manufacturing time, and cost dramatically drop when producing BEVs. 

One of the main components of an electric motor is the motor (stator) housing that is made from aluminium. A special approach is needed to achieve this part’s critical key characteristics of lightweight, durability, ductility, surface finish and precision as well as the geometrical tolerances. The partially hollow form represents an additional challenge and maintaining low cutting forces is essential for roughness and cylindricity requirements.

ISCAR’s complete machining solution for this process has facilitated the transformation from the standard costly lathe-based process to an economical machining centre. The aim is to reduce scrapped parts and reach an optimal CPK ratio. (Process Capability Index- producer’s capability to produce parts within the required tolerance.)

Main Diameter Reaming

The most challenging operation in machining the aluminium stator housing is the main diameter boring and reaming. With the trend to use low power machines, the tool has a large diameter and long overhang and requires creative thinking to minimise weight and spindle load while maintaining rigidity. Exotic materials such as titanium and carbon fibre are used for the tool body, as well as the welded frame design. 

The use of the Finite Element Method (FEM) helps resolve the obstacles associated with this challenging application by enabling the consideration of many parameters, such as cutting forces, displacement field during machining, natural frequency and maximum deformation.

Bearing Seat Reaming 

After Assembly

Unlike the ICE, the electric motor generates its maximum torque from a standing start. This means it does not require a complex transmission system to operate. A simple reduction gear is enough for the average electric vehicle. This reduction gear sits between the stator housing and the gear cover. 

To maintain concentricity between the bearing seats of the stator and gear cover, the reaming operation must be performed in the same machining sequence.

For this operation, ISCAR provides a special ‘push and pull’ reaming type tool with adjustable PCD blades that manage to retain the geometrical tolerances required in different inner diameters on this aluminium part.

Rotor Turning

The rotor consists of many stacked plates of electric steel. Laminated sheets are used instead of a solid body to reduce current loss. The surface must be completely clean of chips, oil, water, dust or dirt. Furthermore, cutting fluid cannot be used, only air. This is a challenge, as a lot of heat is generated on the cutting area and the fragmented chips stick to the surface. Surface finish requirements for this interrupted turning operation remain strict.

ISCAR has overcome these challenges by developing a combined tool with coolant holes both on the top and bottom of the cutting edge to cool and blow away the chips. The two-round inserts are positioned for semi-finish and finishing operations, generating an excellent surface finish.

Battery Case Drilling

As batteries are replacing fuel as an energy source for vehicles, the battery case is an integral component of the design of EVs. Large size and lightweight requirements make aluminium a natural choice for manufacturing this part. But, when dealing with high-end supercars or sports cars, every unit of weight counts. That is why some automotive manufacturers turn to the use of carbon fibre reinforced plastic (CFRP), which offers lighter weight, high rigidity, and lower thermal conductivity than aluminium. 

ISCAR has a wide array of tools specially designed to machine aluminium and CFRP, which provide productive and economical solutions for any application. For example, for the required drilling holes, the SUMOCHAM indexable head drilling line offers a variety of geometries suited for specific materials. For drilling aluminium, ICN heads are designed with a sharp cutting edge and polished rake face. ICG heads feature a chip splitter for better chip removal when working with a long overhang. For drilling CFRP, a special ICF geometry is available with diamond coating. This drilling head is designed to overcome all the typical CFRP machining failures such as delamination. 

The automotive industry has already started changing its direction, moving toward the new challenging era of BEV production. Using ISCAR’s cutting edge technology and innovative solutions will keep the component manufacturers ahead of the industry and help them to adapt quickly to the growing challenges of creating a cleaner, greener, and healthier world to live in.

AI for SME manufacturers

By Robin Hartley-Willows, Co-Founder and CTO of FourJaw Manufacturing Analytics Ltd.

A curious outcome from the national AI strategy

In September 2021, the Government published their National Artificial Intelligence (AI) strategy, laying out their 10-year vision of AI in the UK. Curiously, two key statements caught my eye. Firstly, the UK is already a global AI superpower, with access to talent, a culture of innovation and a progressive regulatory/business environment. The second statement was that AI can increase resilience, productivity, growth and innovation across public and private sectors.

As someone who works with SME manufacturing businesses every day, I know that increased productivity and business resilience are both highly desirable. Many of the people we work with, dedicate their entire careers to the pursuit of these two goals.

But here is the elephant in the room – if AI can fulfil these key business needs, and the UK is already a global AI superpower, then how come we rarely, if ever, see AI providing value on SME manufacturing shop floors? 

The opportunity for early movers

My key conclusion is this – your SME machining business is not ‘late to the AI game’. You could join the first wave of businesses claiming the ‘first-mover’ advantage. In an increasingly competitive industry where lead times, profit margins and quality requirements are all under intense pressure, adding AI to your business toolbox could become a strong differentiator, not for its own sake, but to help you deliver your existing business goals. 

If you’re interested in what AI might look like in your SME business, the rest of this article is for you.

Demystifying the jargon

Before we go further, a jargon buster is much needed. Like most people, you’ll have heard the following terms but struggled to understand how they apply to you. Hopefully, this helps.

Artificial Intelligence (AI) is a technology capable of exhibiting intelligence as we see in humans and animals. For example, learning new behaviours, forming beliefs/opinions, or solving problems creatively. Anything that would make you say ‘Clever Dog’ to your pet qualifies as intelligence – imagine that, but from a piece of technology. That’s AI.

Machine Learning (ML) is a subset of AI that is primarily concerned with learning new behaviours by gathering and processing data. Much like a baby learns to talk through observation, repetition, and trial/error. Learning can be supervised (like in a classroom at school), unsupervised (like a baby putting things in their mouth and deciding if it’s tasty) or reinforced (like getting told off by your parents for wearing muddy shoes in the house).

Algorithms are pieces of computer code that can make a decision. Adding two numbers together can be an algorithm, but so can a complicated machine learning model.

Supervised Learning is a type of machine learning where we know the inputs, we know our desired outputs, but we can’t describe the rules to link them together, and so a computer has to work those rules out for itself. For example, if we have photos of scrapped components and good components, we can supervise a machine-learning algorithm to learn the difference and make predictions for new unseen photos. Neural networks and deep learning both fall in this category.

Unsupervised Learning takes input data and decides how to classify/categorise the data on its own without labels or external help. At FourJaw, we use unsupervised learning upon the power-monitoring data we get from industrial machinery such as CNCs to learn the different states that machinery can be in, and to categorise each of those states as productive or unproductive. Every piece of machinery looks different but unsupervised learning allows us to describe the utilisation, cycle times and downtime of any machine purely by monitoring its power consumption.

Reinforcement Learning is taught by the environment providing rewards for positive behaviours and punishing negative behaviours, leading the machine learning algorithm to get better and better at performing a defined task. You don’t need to define how the task is to be done, only what good and bad look like. This approach has been used to teach robot arms how to pick up and manipulate objects with human-like dexterity.

Where do I get AI from?

If you’ve survived the jargon and have a desire to get started, the natural question is where do you get AI technology from? There are two options:

Develop it yourself

As someone who has learned AI from scratch, I can tell you it is not as complicated as you might imagine. Sure, you can study a PhD in machine learning, but you can also download plugins for Excel and be running your first algorithm by the end of the day. As with all things, it’s a spectrum and the 80:20 rule applies.

If you have someone in-house who is excited and capable on the software side of things, they might be everything you need. Alternatively, you could make contact with an external IT consultancy and work with them to develop your own AI solution. The result will be bespoke software that only your business has, providing a unique advantage. However, you will incur the risk, cost and duration of development which is not to be taken on lightly.  

Buy through products

A lower risk option with shorter timescales and smaller capital cost is to buy-in AI through a third party product. You can quickly assess the product and decide without committing a lot of resources. The downside is that the product won’t be unique to your business, and competitors will also have access to the same technology, so moving quickly and driving internal adoption become important.  

As an example, here at FourJaw, we have built a machine monitoring product that combines AI with a self-install IoT device. It uses the power draw of your machinery to determine utilisation, cycle times and machining capacity. Whatever production challenges you are experiencing, it might be worth a quick search to see if someone has already developed an off-the-shelf solution.

The dos and don’ts of implementing AI

Now we understand the AI opportunity, the jargon and how we might practically get access to AI technology. Finally, several pitfalls apply not just to AI, but to technology in general. To address this, here are three dos/don’ts of implementing AI for SME manufacturers.

1) Tech push or business pull?

Technologists, myself included, are often guilty of implementing tech for tech’s sake, but to businesses that need to defend margins, win work and keep their operations running, this is not a luxury they can afford. Every action they take has to add value and benefit the business. With technology, it’s no different. Simply put, it has to be a business pull, not a technology push.

This brings us to the first (and most important) do/don’t of AI for manufacturers: 

DO: Implement projects that provide quick ROI and measurable business value.

DON’T: Choose far-off, hard to measure or trivial projects that are more fun than functional.

Aligning a technology project to your current business needs is one of the most effective ways to extract short-term value. Here’s why:

-It will be easier to get buy-in from other staff members because they will have first-hand experience of the problem you’re aiming to solve. For example, we don’t know our machining capacity, so we find it hard to schedule and meet lead times. 

–Similarly, you’ll know very quickly if the project is working or not because you’ll have first-hand evidence of the impact on the problem you’re tackling. For instance, we have been able to measure our machining capacity, and this gives us better scheduling and reduced lead times.

–As you can quickly see the results, you can minimise your risk by dipping your toe in with a solution and evaluating its performance over a few weeks or months. If it works, great! Time to roll out. If not, you can cut your losses without much time or money invested.

–Because of the low risk and quick evaluation, you can afford to move quickly, avoid analysis paralysis, and take decisive action to drive your business forward.

2) The minimum viable project

There is a joke in the world of start-ups that any product can be prototyped with an Excel Spreadsheet, chewing gum, a sheet of paper and a mobile phone. It’s a bit of a stretch, but at its heart is an important point – you want to determine if a project has a value very quickly, without sinking time, effort or money into it. Therefore, you should aim for a ‘Minimum Viable Project’ that allows you to do a low-risk evaluation of the general idea before jumping in with both feet.

This brings us onto the second do/don’t of artificial intelligence for manufacturers: 

DO: Create a quick, simple and easy-to-implement solution to prove the general concept

DON’T: Use AI (unless you’ve reached a point where it adds value)

It sounds pretty counter-intuitive, but you’re always better off starting with a rough-and-ready implementation that allows you to learn, iterate and improve within short timescales, rather than trying to dive straight in with an all-singing-all-dancing AI-powered solution that takes years to develop.

Don’t believe me? In which case, let’s look to Google. They have published their 43 rules of implementing machine learning, a dominant subset of artificial intelligence. Here is rule number 1:

“Don’t be afraid to launch a product without machine learning.”

It seems that even the big players in machine learning, value building a simple solution without the bells and whistles to start with, followed by iterative improvements – adding the AI smarts further down the line when they are required.

3) Do what you are doing, but better

If you’ve seen any coverage in the news about AI, the tagline was almost certainly about how it will revolutionise our world, change the way we do business and bring in new ways of working that are beyond our imagination. Whilst I admire the ambition and agree with the opportunities, I feel this messaging is unhelpful. It makes it seem like anything related to artificial intelligence has to be a massive leap, not an incremental gain.

Let’s face it, massive leaps are risky, scary and hard to predict – all of which are barriers to adoption. Incremental gains, on the other hand, are much easier to manage, have more defined value in the short term and are altogether more palatable. When looking at the fundamental technologies of AI, they simply enable us to perform the same computational work we currently do, but with greater speed, greater intelligence, or deeper complexity.

There are very few things that AI can do that you couldn’t do yourself with many sheets of paper and a pen, it’s just that AI will do it millions of times faster with far more accuracy, and without needing a coffee break in the middle. With this in mind, we want to avoid a big leap of faith, and instead opt for incremental progress in the direction that we’re already travelling. With that, we come to our third and final do/don’t of artificial intelligence for manufacturers:

DO: Use AI for incremental improvement of your existing processes

DON’T: Try and revolutionise your business, processes or people with a moon-shot AI project

In manufacturing, we strive for continuous improvement, not abrupt changes. So, it makes sense to aim for the same when it comes to artificial intelligence. The reason this is so important is that technology only really exists to support people, industries and ways of doing business. All three of these gradually change over time, allowing gentle adaption, learning and eventually success through the right blend of novelty and familiarity. 

To summarise

I believe AI can provide genuine value to manufacturing SMEs if the dos and don’ts we’ve seen in this article are kept in mind. I don’t believe AI should be as scary, or as revolutionary as we are told it is. 

Much like a horse, a steam engine, or a car can get us from A to B with various levels of speed, I believe AI is just a new tool to support manufacturers in doing what they already do, but better.