Oracle AP&T Technical Article AP&T Technical Page 8 Member News: MPPS Page 19 Skills Competition Results Pages - 20 & 21 Issue: Autumn 2019 £10.00 (FREE to members) (ISSN 1019-AUT2)

of Sheet Engineering Journal of the Institute Principle Officers

President Mr Alan Shaw

Chairman of Council Mr Barry Smith

Honorary Treasurer Mrs Josie Stevenson Skills Competition Report - P20

Honorary Secretary Mr Bill Pinfold t. 07981 499 146 e. [email protected]

Social Events Mr Adrian Nicklin t. 07774 260 126 e. [email protected]

Advertising & Editor Steve Watson t. 01384 505 656 e. [email protected] impact Much has been made of Brexit’s but manufacturing on British exports, to on its ability heavily in Britain relies imports are import. Almost half of the UK’s a final product. made into are goods that Barry Smith, Chairman of the Council

2 Cover photo courtesy of AP&T Contents

Principle Officers...... 2 President and Chairman Reports ...... 5 From the Secretary ...... 7 AP&T Technical Article...... 8 Dutton Simulation Technical Article...... 10 ISME Events: HSG236...... 14 Metal Bashers Ball Report...... 17 CBM H&S Group Meeting...... 18 Member News: MPPS...... 19 Skills Competition Results...... 20 MMMA...... 22 Environmental Issues...... 26 Special Report: Bruderer - 3 Presses in 1 28 Calling Young Members...... 31

Are you following The Oracle published in association us on with the Metalforming Machinery Twitter? Makers Association Ltd. ISME & MMMA Join the working together for the benefit of the Sheet Metalforming Industry. conversation The Oracle, mouthpiece of the Institute, speaks for and to the world of & Pressworking by way of featuring New, Views and Topics around the Industry.

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Hydraulic Presses Hydraulic Presses Hydraulic Presses

Coil Handling Coil Handling 3 in 1 systems 3Coil in 1Handling systems Decoilers Decoilers3 in 1 systems Straighteners StraightenersDecoilers Feeders FeedersStraighteners Feeders Alan Shaw - From the President President Dear Member, Whilst pondering possible subject matter for my However, Wikipedia goes on to explain that there President’s notes for this edition, I decided to are conflicting stories as to exactly how Pythia check my understanding of the meaning of the delivered her prophecies. One suggestion being word “Oracle”. that she “became in a frenzied state induced by vapours from a chasm in the rock, and that she Wikipedia has the following entry, which I have spoke gibberish which priests interpreted as the edited in the interests of brevity, enigmatic prophecies.” “The Oracle of Delphi, as the ancient Greek Regrettably, to my knowledge, ISME is not Goddess Pythia came to be known, was widely blessed with priests endowed with interpretive credited for her prophecies over a period powers, so lets just hope that this edition’s spanning 8th to 4th Centuries BC - inspired as content is as clear, erudite, concise and she was by being filled by the spirit of the god, informative as we have all come to expect. Apollo. During this period the Delphic Oracle was the most prestigious and authoritative Alan Shaw - President oracle among the Greeks, and she was without doubt the most powerful woman of the classical world.”

Barry Smith - From the Chairman of Council Chairman Much has been made of Brexit’s impact on British The increase in customs costs and traffic jams at key exports, but manufacturing in Britain relies heavily on points of entry and exit stemming from Brexit will its ability to import. Almost half of the UK’s imports have impact to the UK automotive manufacturers. are goods that are made into a final product. The just-in-time parts delivery, that we are all familiar Therefore, supply chain management is critical for with, which was designed to minimise inventory UK companies that want to successfully navigate costs and keep factories humming efficiently will be through Brexit and beyond. In some cases, it could affected. Every company currently trading is facing determine their survival. concerns as to the future trading conditions and how this could affect them. Some companies have been forced into making the decision to increase their stock levels by their I believe that we all represent an important part of customers and by introducing stocking policy puts the supply chain network and the sooner everyone increased pressure on cash flow. This is yet another knows what the final outcome of Brexit is the better burden that the manufacturing sector face who can for us all. ill afford it. I don’t think anyone knows what is going the happen Even by putting new stock levels in place, this in regards to the outcome of Brexit, one thing for may not eradicate the bottle necks relating to the sure is, whatever the outcome, we all will have to transportation and export of these manufactured adapt and do whatever is necessary in the traditional items. British true grit approach.

5 TMA A4 V1.qxp_Layout 1 22/08/2016 14:53 Page 1 NEW POWER PRESSES

50 years’ service for Master Craftsman John Davies MISME

John works as a Master Armourer at the oldest UK manufacturing Exclusive distributor company, Firmin and Sons Ltd in Birmingham. Firmin was for UK and Europe established in 1655 and make ceremonial buttons and armour by hand and previous customers include Admiral Lord Nelson and the Duke of Wellington. They are currently the Official Armourers to the Queen’s Household Division and John specialises in making the helmets and breast plates worn by these men. • From 6-2,000 tons • TMA designed electrical control John started at the company as an apprentice and • World Precise Machinery Group circuit for complete support has recently completed 50 years service which was power presses • Pilz PNOZ Safety PLC marked by an award by his company which was featured on several BBC News bulletins in August. A • Non-standard strokes available • Pilz light guards (option) short video of John making a helmet can be found on • Latest technology wet multi-plate • Automatic lubrication the BBC web site by searching for “Firmin and Sons”. clutch/brake • CE marked In it, he says he loves his job but every handmade helmet is a challenge. • Hydraulic overload protection • Warranty and support by TMA

John has been a Senior Judge at the ISME Skills Competition for many years and he donated a half size model helmet as a trophy for the Open Class to be awarded annually. TMA are the UK’s NEW TMA SERVO FEEDS largest independent • Electronic servo roll feed power press service • Up to 24in wide material and repair company • User-friendly touch screen Contact us for all your power display press requirements • Pilot release • Sales • Service • Handheld remote jog station • Spares • Repairs • Pneumatic roll pressure • Maintenance • Designed, built, programmed and fully supported by TMA +44 (0)121 328 1908

TMA Engineering Ltd, 95-111 Tyburn Road Erdington Birmingham B24 8NQ UK Tel +44 (0)121 328 1908 Fax: +44 (0)121 322 2017

www.TMApresses.com [email protected] Estd. 1973 12 13 Bill Pinfold - From the Honorary Secretary 2019 Secretary Another busy 6 months for the Institute with an Honorary Member at the September Council the Metal Bashers Ball, Skills competition and Meeting. HSG236 meeting. At the September Council Meeting is was agreed that ISME and MMMA will hold the 2020 Metal Bashers Ball on Friday 15th May at the Copthorne Hotel, Dudley. Further details will appear on the ISME web site and the Twitter feed. John Davis, Council Member, Past President and Past Chairman has decided that the time is right to leave Council to make way for younger members to take up the baton to move the Institute forward. John was ISME Chairman After eleven years of very efficiently organising 2002-2004 and ISME President 2010-2014 and ISME’s events, Adrian Nicklin has decided to even had a short spell as Oracle editor when the stand down as Events Officer. His expertise previous editor left at short notice. His company will still be available to us as he will be joining Davis Decade always supported the Institute’s Council but we are looking for ways of replacing activities and with his wife Jan attended all our his leadership either by one individual or social functions. John’s wise guidance will be splitting the job up. Anyone interested, please much missed by his colleagues. In recognition contact me at [email protected] for of John’s service to the Institute he was made further details.

New Member AGM Report

We would like to welcome the following Report on ISME 73rd AGM held on Thursday 19th May 2018 new member to the Institute: The meeting was kindly hosted by Company Member Regent Engineering and was attended by 8 members. Peter Grant The Hon. Treasurer, Josie Stevenson reported a losss for Peter Grant has joined as a 2018 of £6,774 with reserves decreasing to £19,239. Member. Peter is The figures were due to a change in accounting period which had inflated the 2017 results at the expense of 2018. Managing Director The Chairman, Barry Smith gave his report on a year of Hitherbest where several successful events had been held. Sheet Metal The following officers were elected: Fabrications Ltd. • Chairman Barry Smith • Hon. Treasurer Josie Stevenson in Telford. Peter • Hon. Secretary Bill Pinfold • John Yarnall was co-opted brings a wealth to Council. of business experience to Member News the Institute. Skillcraft products have continued their investment program with the purchase of an Amada EM3612 press and a Hypertherm XPR170 machine.

7 AP&T launching TemperBox®

A new cycle time neutral production solution that enables tailored properties in press hardened components.

AP&T is introducing a patented solution for partial press hardening of structural parts for passenger cars. TemperBox® allows hard and soft zones to be combined in a single part, paving the way for innovative body designs and cost-efficient production. TemperBox® can be integrated with AP&T’s new and existing Multi-Layer Furnaces as well as with any other type of heat treatment equipment. With over 100 press hardening line installations for customers all over the world, AP&T is now taking an important step in the development of its press hardening technology. The company’s most recent product innovation — TemperBox® — offers entirely new opportunities to design and produce structural AP&T’s patented furnace module for partial parts cost efficiently. hardening, TemperBox®, can be installed in AP&T’s new and existing Multi-Layer Furnaces, and is also The patented invention TemperBox® is available for any other type of heat treatment based on what was originally developed by equipment. Agim Ademaj, (Metakus Automotive, Kassel, Germany). In 2013 a cooperation initiative between AP&T and GEDIA Automotive Group (Attendorn, Germany) was launched for the further development and industrialization of The process involves precision-controlled the technology, which has now resulted in a heat treatment, which takes place in a special fully commercial solution. furnace module known as TemperBox®. After “The patented solution enables several being heated up to 930 degrees Celsius in a material properties to be combined in a single conventional austenization furnace, e.g. AP&T’s finished part. Some sections can be hardened Multi-Layer Furnace, the blank is moved to to maximize strength while others are made the TemperBox®, where selected sections softer to achieve the desired ductility and are blocked from radiation and cooled down to facilitate post processing such a joining while the rest of the part is kept hot. The blank or mechanical cutting,” says Dr. Christian is subsequently formed and quenched to Koroschetz, CTO at AP&T. produce the finished part.

8 section. properties monolithic with cross overthe when producing press hardened components industryisaccustomedtotoday range asthe same inthe enablesshortcycletimes solution hardening TheTemperBox® lines. production press innewandexisting as easyintegration compared totoday’s press hardening such offers clearproduction-related advantages safety ofbodyparts.Thenewmethod implemented toimprove collision the hardening tools,whichare frequently processes suchtailored temperinginpress reinforcementscostly intensive orcycletime can workmore freely considering without designers andmanufacturingengineers component.Thismeans performance ofthe properties, required customizedtothe The final tailored isapartwith result Facts by the endof2019.GEDIAhasalsohadaTemperBoxby the properties for variousEuropean OEMs. Production isplannedtostart used forproduction ofpress hardened tailored componentswith GroupGEDIA Automotive Germany, inAttendorn, where be itwill The first full capacity The firstfull TemperBox owner ofanexclusive production European for the license market. technology. patentrightsandGEDIAisthe ownerofthe AP&Tisthe In Europe, TemperBox GEDIAandAP&Tcloselycooperateonthe in usesince2017. and softzonestobecombinedinasinglepart. Precision-controlled heattreatment hard allows Koroschetz market, regardless ofbrand,”saysChristian anypress basically with hardening inthe line newtechnologycanbeused “This meansthe typeofheattreatmentany other equipment. available forpress hardening have that lines Furnaces,andisalso Multi-Layer and existing TemperBox® inAP&T’s canbeinstalled new example.” for lasercutting, is muchlessexpensivethan —which methods trimmed usingconventional tobepunchedor them be keptsoft,enabling areas component,suchasflanges,can ofthe processing isalsomucheasiersincespecific performance designare possible,post incrash “Not onlynewpossibilities ® production line will be installed at production at beinstalled will line ® prototype line prototype line ®

Using Forming Simulation to Compensate for Springback

Simulation of sheet metal Modulus (E value) of the material which directly has been in use for more than 25 years. The influences the amount of springback (figure method requires input data including the 3). All ferritic steel have approximately the geometry and material specification for the same Young’s Modulus, but high strength blank, CAD models of the tool geometry steels will exhibit more elastic strain than mild and process conditions such as blankholder steels simply because of the higher stress levels force. Within a couple of hours a great reached; and Aluminium will tend to show more deal of knowledge about the feasibility of springback relative to steel simply because the proposed process and tool design can it has a Young’s Modulus three times lower be obtained. The results reveal potential (~70GPa cf. ~210GPa). problems with splits, wrinkles or excess One of the more advanced capabilities of thinning (figure 1) as well as allowing forming simulation is the ability to calculate optimisation of the process to determine the springback distortion. International benchmarks optimum blank size and number of operations such as the NUMISHEET conferences (figure – many toolmakers now rely on simulation to 4) have focussed on this challenge leading to confirm the process before physical try out. the development of advanced techniques and Besides splitting and wrinkling, one of the major more sophisticated material models. These forming defects facing the design engineer is improvements mean that today’s simulation springback – the unavoidable change in shape engineers are increasingly confident in their due to the recovery of elastic strain in the blank springback calculations. after removal from the tool. This leads to a If we can accurately predict springback then variety of distortion modes including doming, the next logical step is to use the prediction wall curvature and incorrect flange angles to correct for the problem in the first place. (figure 2). The main problem caused by this This capability has been added to a number distortion is poor part fit in assembly especially of specialist forming simulation solutions, where mating surfaces are out of tolerance, as including eta/DYNAFORM based on the LS- well as other issues such as panels becoming DYNA solver (figure 5). The initial analysis is stuck on the tooling and cosmetic defects in done with tooling design to the nominal CAD skin panels, sometimes referred to as “teddy for the part to obtain a baseline springback bear’s ears”. Manually correcting for springback result. Then, the difference between target distortion creates costly delays late in the geometry and the initial springback shape development programme and may even lead to are used to generate a new tool shape. A tools being scrapped. scale factor is used – rather than take the full The amount of elastic strain in a pressing is difference it is generally found that an amount a function of the elastic stiffness or Young’s less than 100% will get closer to the desired

10 result – 100% usually goes too far the other way. and can lead to a further change in shape; A new simulation is then run from the updated compensation can be applied to the initial tool shape and the result checked again; further drawn shell, the trimmed panel or potentially iterations may be necessary depending on the both. The user should also consider how material and of course the required tolerance the part is fixed for checking as the clamping in the result. With eta/DYNAFORM this entire process may alter the relative movement in the process can now be automated by specifying panel; it may even be necessary to consider a target tolerance and allowing the software to gravity in some cases and check the geometry iterate until this is achieved (or the maximum with the panel oriented as it would be in the number of iterations is reached). final assembly.

Dutton Simulation has been applying this If a panel has already been produced from an method for over a decade and the results have initial try out tool then it is also possible to use been extremely encouraging. One of the first this result for the compensation method. By applications was an automotive side impact scanning the geometry of the formed panel, beam pressed in 1180MPa steel (figure 6). It e.g., using a white or blue light method, we required a number of iterations but the final can determined the difference between actual outcome proved to be acceptable, saving and target geometry and use this as the basis considerable time and materials at tool try out. for the compensation process. This also There are a number of other considerations offers an opportunity to validate the predicted needed to get a compensated springback springback from the model, checking sensitivity result. Trimming, especially with a draw to inputs such as material properties, friction process, releases certain regions of the part and blankholder force.

One of the more advanced capabilities of forming simulation is the ability to calculate springback distortion.

>

SPRINGBACK

It should be noted that there are a number of Control of springback is a major challenge – limitations to the springback compensation it is inevitable, though more severe in some method. Firstly, the result is generated materials than others, so we need an approach using a single set of material data whereas to deal with it. Good practice in part design, in reality properties will vary within the range process engineering and tool design should allowed by the specification – and this can not be overlooked, helping to limit the be considerable; springback is particularly problem with stiff geometry and sufficient sensitive to material yield strength for example. plastic strain during forming. However, now So the compensation needs to consider that we have the ability to accurately predict what values to use – worst case, mid-range springback shape, engineers can address or something else? Other limitations include this most challenging of issues in sheet metal possible confusion over wrinkling – the process forming using an analytical approach. may attempt to change the tool shape creating Compensation using a simulation model has “inverse” wrinkles; the method does allow been shown to get tools much closer to “right regions to be omitted to avoid this. And first time”. This has resulted in reduced time undercut, i.e., die-lock conditions, can result required in try out, saving money and materials from applying compensation where bend and allowing Job 1 production to be achieved angles beyond 90˚ can be accidentally created; on time and budget. again, the LS-DYNA method has options to avoid this.

download the full presentation from isme.org.uk/isme-resources

About the author: Trevor Dutton, C Eng MIMechE MISME, is Director of Dutton Simulation Ltd, now in its ISME Member Trevor Dutton and his wife Julie headed 17th year. The company provides off in September on a trek in the remote highlands of a range of forming simulation Iceland, traversing mountains, rough terrain, hot springs software from leading suppliers and lava fields, all in support of The Love Hope Strength from around the globe, as well as Foundation. A report and pictures will appear in the next offering a tool process analysis Oracle. Further details can be found on“Trevor and Julie’s service for customers. Dutton Iceland Rocks” page on Just Giving. Simulation also present technical training courses to enhance understanding of metal forming.

13 July 2019 Events HSG236

Steve Garrett, Engineer Surveyor Power Press, Allianz PUWER contains a number of regulations with Reg Engineering gave an update on HSG236 Power Press 31 covering Power Presses working hot metal and maintenance and thorough examination to over 40 those be operated with “Safe Strokes” less than 6mm. ISME members and guests at the event which was Regs 32-35 cover Power Presses on matters such as Thorough Examination, Regular Guard Inspections, hosted by MPPS Ltd at their Tipton assembly shop. Competent Persons and the keeping of records. Steve gave a briefing for all users of Power Presses ACOPS or codes of practice give guidance on on the requirements to conform to current regulations. use, have special legal status and can be used in As background Steve said that in 1943 there over 500 prosecutions. reportable accidents due to Power Presses. There are numerous BS and ISO standards and Guidance Notes. Guidance Note HSG236 introduced In 1965 the Power Press Regulations were introduced in 2005 is of particular importance to users. The later incorporated into the H&S at Work Act and main changes it bought in affected electrical testing PUWER in 1998. By this time reportable accidents and the need to have complete circuit diagrams. were down to 20. At the same time the number of Any movement or modification of a press requires Power Presses in the UK had fallen by 60% from the reinspection to HSG236. It also gave the need for the post war peak. Competent Person to ask for the exposure of critical

14 July 2019 HSG236

parts such as clutches and brakes and for visual or NDT tests to be performed by a suitably qualified person. HSG316 covers light guards.

SAFed Guidance Notes for Competent Persons are also useful.

A lively Q&A session followed with the definition of a

Competent Person and the Guarding of presses used HSG236 for hot working amongst the subjects discussed. Steve was joined for the questions by his colleague, Roland Zumpe, Specialist Engineer Hazardous Machines also from Allianz Engineering.

The evening was completed by a demonstration by Steve of the Magnetic Particle Inspection Process which involves a strong magnetic field being applied to a component which has previously been sprayed with a solvent containing iron filings. If there is a crack in the component it is revealed by a line of filings

gathering round its length. HSG236

A very informative evening much appreciated by the attendees as was the excellent buffet provided by MPPS Ltd.

The main changes it bought in affected electrical testing and the need to have complete circuit diagrams. Field Service Engineers Looking to (Electro-Mechanical) bridge the skills Technical gap or solve Sales staff shortages? Engineering If you manufacture, distribute or sell within Sales the automotive, industrial or engineering markets, we can recruit for you. Established over 20 years we are industry specialists with a team of ethical and experienced recruiters. Project We recruit locally, nationally and Engineers internationally. Preferential rates for ISME, MMMA and CBM members.

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Toolmakers

MEMBER Metal Bashers The Metalforming Machinery Ball Report Makers Association

Together, we should all celebrate what we in the UK are good at!

May 17th the second annual Metal As always, these events are not only a members- Bashers Ball dinner dance, hosted jointly by only affair, they are open to non-members as the MMMA and the ISME at the Copthorne well and indeed not only from metal forming hotel, which saw over 160 guests from over 25 industries, but to the wider manufacturing member companies join together and celebrate fraternity as well. If you would like to join us next contributions to UK Manufacturing. year, or to find out more about the MMMA and ISME organisations, we’d love to hear from you. To ensure this event was a success takes a lot of careful organisation to ensure everything from Together, we should all celebrate what we in the venue, food, drinks etc are all up to scratch. the UK are good at! Many thanks to those involved in the organisation, Adrian Haller Chairman of the MMMA & Bill Neal also of the MMMA, and Bill Pinfold, Adrian Nicklin and Josie Stevenson of ISME. We are sure everyone who attended will agree it was great evening and a good chance to catch up with colleagues and peers, new and old alike.

A very Special thank you to our sponsors this year Schuler Presses, the MTA, eleven10creative and Close Bros Asset Finance, who’s much valued contribution to this years event helped it to be such a big success. As those of you who attended will know, this years special guest was Carl Chinn MBE, a local historian who gave us all a great insight into local gangsters, the real Peaky Blinders. Many thanks to Carl for taking time to join us on the night. And lastly but by no means least, a big thank you to everyone who attended the Metal Bashers Ball and here’s looking forward to the next event! Special guest was Carl Chinn MBE

17 CBM H&S Group Meeting

The main topic of the meeting was the HSE Dust and fumes from the process were safety bulletin issued early this year about a hazard with very small particles remaining the change in enforcement expectations in the air for up to 42 hours. This presents a for control of weld fume. All weld fume potential hazard to supervisory staff and third (including mild steel) is now classified as a parties who are not wearing protection. carcinogen which can cause lung cancer and The HSE have been criticised in some quarters has the potential to cause kidney cancer. for not giving full guidance on particle sizes This is based on the outcome of recently and exposure levels. A new note containing published research by the International guidance is awaited. Agency for Research on Cancer (IARC). Consequently, there is a strengthening of the Scott completed his talk with a demonstration HSE’s enforcement expectation for exposure on the latest ventilated welding helmets. control for all welding fume including mild and Colin Bennett of Sertec talked about the stainless steels, high chrome steels, armour problems and risks associated with turning and exotic materials. steel coils.

Scott Blacklock of 3M Healthcare gave a A sub committee was set up to give feedback presentation on the subject saying there to the HSE on HSG236 which relates to Power estimated to be 190k people employed on Presses. The committee met in September welding in the UK of whom 70k were skilled. along with representatives from the CBM. The fatal accidents reported in the work place each year only represented 1% of total industrial ISME, MMMA and SAFED and an agreed deaths with the rest due to chronic illnesses. document has been submitted to the HSE.

Dust and fumes from the welding process were a hazard with very small particles remaining in the air for up to 42 hours. Member News Investment in Black Country extension helps MPPS press forward

One of the UK’s leading specialists in mechanical power presses has doubled its capacity after investing in a new building in Tipton. Midland Power Press Services (MPPS), which provides repairs, spares, inspection and upgrades on over 100 different machines, now has over 10,000 sq ft of space split across dedicated and fitting shops.

The £300,000 investment on the expansion and the CNC machines comes on the back of a sustained period of growth, with new contracts from the , automotive and white goods sectors helping it push towards £3m operation to a business employing a 30-strong turnover – the best 12 months in its near 30-year team of skilled engineers. history. It has also signed an agreement to become the In addition to the second site, the company exclusive UK sales agent for OMERA, an Italian- has also bought a new Versa-Lift for £150,000, a based supplier of beading machines and presses. unique forklift that has an extendable frame to help with the smooth and safe lifting of heavy This means for the first time that Midland Power machinery. Press Services can provide new equipment ranging from mechanical and hydraulic presses to Josie Stevenson, Company Secretary at Midland fully automatic lines. Power Press Services, commented: “We have had an excellent 12 months as more manufacturers are “The recent open day was a huge success, looking at keeping their existing presses working attracting over 100 people,” continued Josie. longer and that’s where we can really make a “There has been a lot of changes here and we difference. wanted to show new and existing customers/ “Our team of engineers can refurbish, repair, suppliers exactly what we can offer, including service and upgrade over 100 different types of the new machining shop and the state-of-the-art power press and this expertise has seen us win design software we are using to help identify work for the likes of GKN, Glen Dimplex, Stadco, issues for the customer.” Tata Steel and Federal Mogul.” She concluded: “If the order pipeline continues as “The growth has also necessitated the need for it is, we’ll enter our 30th year on course for £4m.” five additional people, including a new Health and MPPS, which is working its way towards ISO 9001 Safety Manager.” accreditation, is a real family affair, with Josie’s Established in 1980 in a small workshop in partner Bob Crow at the helm with her, alongside Wolverhampton, MPPS has grown from a one-man daughter Ruth Harper and sons Paul and Simon.

19 Skills Competition 2019 Report

The 2019 ISME Skills Competition was held We must praise the skills of the Apprentices on Thursday 13th June 2019 at Morgan for their workmanship and quality. Dimensional Motors, Malvern. accuracy of the test pieces this year were to a very high standard with marking very close in all With Thanks to Morgan Motor Company categories. The Open Class entries as normal especially Angela Hymas and the helpful & gave the Judges a challenge to identify skills knowledgeable staff, the event was a great and originality. success at the Malvern Plant that promotes UK Engineering hand working skills to the highest ISME also judge their written technical level. document that accompanies the component they have made. We believe that the written This year’s event bought in 26 apprentice word is an essential part in the planning of how competitors from the West Midland and South they go about producing their exhibit. Coast showing the need for the future to make all our metal commodities whether for Like all events in today’s environment we are aerospace, ship building, automotive, indebted to our event sponsors; catering or retail sectors. • Morgan Motor Company With Competitors from, Babcock Marine, • Institution of Mechanical Engineers (ImechE) Sertec & Warwickshire College we had a good • Midland Power Press Services mix of test pieces to judge. • Confederation of British Metalforming (CBM) • AP&T Group • Bruderer • Babcock Marine

The Categories were; Without their support there would not be • Wall vent year 1 a competition. • Ducting year 2 • Tool Box • Open class exhibit

20 View the full winners gallery isme.org.uk/isme-2019-competition

Overall Winner with the ISME Trophy Rhys Jones Babcock with ISME President Alan Shaw

THIS YEARS AWARD WINNERS ISME Trophy Overall Winner, went to Rhys Jones from Babcock. While Judging took place the Contestants, Trainers & Guests enjoyed the very interesting We thank all the ISME & ImechE Members with Factory tour noting the skills of the Morgan guest retired engineers for doing the Judging Workforce in production. As previously which included measuring and project mentioned the ISME judges thought the reading. quality standard was exceptionally high with Thanks, must go to the College and Company the following awards given; trainers for the time effort and support Wall Vent Test Piece Winner (Frank Cooper they give to the students and apprentices. Award) was a tie for 1st place Connor Kent Without their commitment there would not from Babcock & Jack Owen from Sertec. be a competition. We will be discussing the 2020 competition and venue at our next ISME Wall Vent Test Piece Written Winner, Jack Owen from Sertec. Council meeting in September. Ducting Test Piece Winner, Reece Arcos We will keep you posted through our website from Babcock and social media. Ducting Written (Ted Rosmarin Award) Dominic Brewster from Warwickshire Entrants to the ISME Skills Competition are given was a shared student membership of the Institute for a period Toolbox Test Piece & Written where they receive the ISME Oracle to keep them project completed by Ryan Bevan & Hadden in touch with our activities to hopefully encourage Demming from Sertec them to join us as their careers develop. This year we Open Class winner, welcome Reece Arcos, John Davies Award Ryan Chapman, Jacob Dear, Rhys Jones, Connor Kent, Rhys Jones from Babcock Dan Meyer, Sam Ryan and Aidan Woodall of Babcock. ISME Originality Open Class Award went to Declan Boylan, Jake Cogin, Mason Collins, Thomas Dan Meyer from Babcock Grainger, Aman Guddu, Charles Horsbury, Luke Jones, Jack Owen and James Pugh of Sertec. Open Class Written Award went to Dominic Brewster, Nathan Claybur, Bendict Davies, Jacob Dear from Babcock Jordan Marston, Joshua Mitchell and Eric Szasz from Warwick College. The Metalforming Machinery Makers Association

MACH 2020 MMMA Metal Working Village

The MMMA ‘Metalworking Village’ at Springs, Press Techniques, Helm, AntonSaws, MACH 2020 will be the largest area taken QualiMach, Wilson Tool, Pressform Machinery, by the MMMA and has already exceeded Ortlinghaus, Decade, Group Rhodes, Oerlikon expectations of members attending, with 23 Balsers, Voith Turbo Ltd, Formit. confirmed and more to be confirmed. As the The excitement of being part of the Metalworking original space for the ‘Metalworking Village’ Village begins now as companies start to plan has been filled, as and when more space is the stands and the technologies, products and requested by members, additional space will services, they will be exhibiting. to be requested. Overall 23 members will be there, hoping to This is a fantastic result for the Association and be even busier than they were in 2018, which makes the ‘Metalworking Village’ space taken was a great exhibition for members, both from to around 650 metres. This is the fourth Enquires and orders placed during and post the largest in the entire exhibition halls. exhibition. At present, Members exhibiting are: Whilst planning your visit to MACH 2020. Make Esprit Automation, Cotswold Machinery, sure you take time out to include a visit to the Worcester Presses, Bruderer, Schuler, Presscare, MMMA – Metalworking Village, it will be exciting TMA, Roemheld UK, Industrial Clutch, Kaller to see the technologies there on display.

22 MMMA Member Feature

Can you tell us about the history of Worcester is required Worcester Presses? Presses hold a number Worcester Presses was founded in 1932 as a of presses available at division of Jones and Attwood. The Company our new works in Dudley. was originally set up to manufacture 2 ton to 50 ton mechanical power presses, but as the years What is the main service you offer? progressed, it expanded into other areas. In 1990, Our main service is the supply of mechanical, we became the UK and Ireland exclusive agents hydraulic power presses, coil handling equipment, for Chin Fong mechanical presses and in 1998, after sales services and spares. became exclusive agents of Tomac coil handling equipment. 2005 became a Limited Company and have continued to expand. Fast forward to 2008, we became exclusive agents for Yeh Chiun hydraulic presses. Most recently, adding Lee Yih in press transfer systems to our range and moved to new premises in Dudley allowing us to offer complete press line assembly in house.

What does Worcester Presses specialise in? We specialise in Worcester mechanical presses, Chin Fong mechanical power presses and Yeh Chiun hydraulic presses, also Tomac coil processing equipment, and a variety of press shop ancillary equipment.

What makes Worcester Presses stand out from our competitors? What are your company values? We stand out from our competitors because of To exceed customers’ expectations on value, our technical support, on-site back-up by a team quality, technical support and service back up. of trained engineers and our comprehensive 6-12 month service packages tailored to suit customers’ What can we expect from Worcester Presses at needs. We also have over £100,000.00 of spare the MACH 2020? parts in our central stores for rapid response and a We have increased our stand space to give manufacturing department in-house for machining Worcester Presses a more customer focused area – of parts from raw material to finished product. We plus, there will be new equipment to allow visitors invest in apprentices and are quality assured ISO to interact with during the MACH exhibition. 9001: 2015. Worcester Presses also hold a range of presses available from stock at our works in Dudley. Why did Worcester Presses choose to join the MMMA? What is something not many people know about We have been a member for 40 years. Originally Worcester Presses? it was only for manufactures of equipment directly Our directors have over 80 year’s combined involved within our market sector that worked well knowledge of Worcester Presses and products. We in the early days. However, MMMA has developed carry parts in stock and our engineers are available in recent years and opened up the member’s for call–outs 24 hours day. Our new premises criteria allowing different market sectors to become comprise a 6,000 sq ft factory which allows us to involved – which inturn has made the MMMA a deliver turnkey packages that reduce downtime great marketing force that we are proud to be a on customer sites. If a standard press specification part of. The Metalforming Machinery What it means Makers Association to be a MMMA member

Coverage on MMMA Social Media Be a part of an Substantial channels, including association dedicated preferential stand Instagram, Twitter and to the metalworking space rates at the UK’s LinkedIn and a free industry and allied major metalworking monthly banner on sectors exhibition (MACH) the MMMA homepage

Innovative, flexible Networking and targeted Funding opportunities packages and across the UK’s Business support Manufacturing guidance sector

Access to preferential, cost Preferential Opportunity to be part effective recruitment Commercial and of the UK Reshoring through a Professional Business insurance Programme Recruitment rates Partnership

Take advantage of a Free advice and company car leasing seminars on HR and and finance packages employment law

All this for less than #mmma the price of a coffee www.mmma.org.uk per day

24 Technologies The Metalforming Machinery Makers Association and Services the MMMA cover in UK Founded in 1949 then known as ‘’The British Power Manufacturing. Press Makers Association’’, to constitute and maintain a central National Organisation between all those • engaged as Manufacturers in the Power Press making • Waterjet cutting and Allied Industries. • Metal Cutting • Automation In 1971 it became the MMMA areas of business, that include:- • Mould & Die Design and to enable the Association Insurance, Finance packages, Manufacture to expand its activities to Health & safety, HR, Legal • Tool and Mould Making encompass manufacturing Advice, Training, Car leasing, • Metal Forming companies outside of the UK. Recruitment etc. • Press Manufacturers and This has now been opened to Machinery companies providing a wider MMMA work very closely • Press Ancillary Services range of services. with the MTA to promote the • Training ‘Metalworking Village’ within • Sawing & Cutting Off The MMMA is the only the MACH exhibitions. Where • Magnetics association to represent the members have the opportunity, • Injection Moulding needs of the ‘Sheetmetal to participate in the UK’s largest • Lifting and Assembly Industry ‘ more recently, manufacturing technologies • Monitoring meeting the needs and exhibition at substantial • Rubber Moulding expectations of companies preferential stand space rates. involved with associated MACH 2018 attracting over technologies. The MMMA now 25,000 visitors over 5 days. embraces ‘UK manufacturing’ Every exhibiting member has and continues to offer, great the opportunity to engage with value for money and cost- these visitors allowing them effective Marketing to help to demonstrate the depth of promote and encourage, Technology available through innovation and productivity the ‘Metalworking Village’. within the Manufacturing sector. In addition the MMMA have MMMA ‘The Metalforming partnered with Specialised Machinery Makers Association’ companies which offer is rapidly becoming the members, support, advice Association to be part of - and encouragement in many Why Not join today? Environmental Sustainability Issues within the Sheet Metal Forming Industry John Yarnall CEng, CEnv MISME

Pollution prevention, eco-efficiency, eco- can conserve materials and reduce their innovation may all be interpreted as steps in own costs. It is generally pleasing to not that most the direction of environmental sustainability. raw sheet metal supply from Europe has Compliance to new guidelines for industry, and had some recycle processing already. But this is is now mandatory to meet environmental laws not necessarily the case for sheet materials and standards. These new laws now reflect on purchased via Asia to produce product. how manufacturing impacts via its services and Dangerous Chemicals: The process to form products on the environment. The main and fabricate sheet metal uses different solvent, purpose of legislation is to make sure surface treatments, cutting agents and forming that businesses that manufacture and sell oils. These chemical and oils are often toxic by products are responsible for their end-of-life nature, and are hard to work with and difficult to environmental impact. dispose of safely. This can create environmental Exploring Environmental Sustainability Issues hazards within the manufacturing plant, and within with sheet metal forming and fabrication. the local community. Researchers have been Although it is a necessary part of modern looking into ways to minimise the impact of these manufacturing, sheet metal and its fabrication it is processing chemicals by investigation not an environmentally friendly industry. Over the suitable more eco-friendly alternatives that might past several years, sheet metal technology be substitutes. and techniques have created ‘greener processes’. Sheet metal makers often need It’s easy to find examples of ways that the Water Use: to use water in various makeup fluids as dust industry has worked to consume less power, rely suppressants, coolant/ process lubrication, and less upon toxic chemicals, consume less cleaner. In some areas, this reliance upon fresh water, and to generate less waste. water adds an expense and even puts a drain The Key Issues: upon on a critical resource. Some examples include desalination of sea or grey water. Power Use: The processes that have to be used to change sheet metal into useful Reductions of reliance upon fresh water can also products consume a lot of energy. Each stage lower costs and help make sheet of the process, including any actual fabrication, more sustainable. transportation and distribution, consumes its Handling Waste: Lots of non-degradable waste own share. To save money and help with the by-products are formed during the sheet metal environment, many manufactures have begun forming process. The problem of waste recycling to look into more eco-friendly technologies and and disposal certainly isn’t the huge problem as in business processes. the past years. However, there is still more work to be done with many issues of Use of Raw Materials: It can be said that at the present time many sheet metal products come waste handling to be fully addressed. from non-renewable resources. These include ore Society for The Environment (SocEnv) and minerals. Good recycling of these materials There are now many professional licenced advisory bodies now able to advice on environmental regulations as applicable to can help somewhat with the issue of using raw manufacturing. In the UK SocEnv, with more than 7,400 registered materials in a sustainable way. Sheet metal practicing Chartered Environmentalists (CEnv) and Environmental Technicians (REnvTech) registrants, offer advice and registrations manufactures that focus upon reuse and recycling through their Licenced Professional Bodies.

26 ONE NAME - A MULTITUDE OF POSSIBILITIES

in addition to new presses we also supply pre-owned high speed ‘precision’ presses and feeders

We also provide a range of servo feeders to SUIT ANY Pre-owned presses requirements, FOR MATERIAL up to 15mm thick and available from stock two meter wide, for any power press.

‘Free’ Press tool trial capabilities available at our UK HQ, enabling Full refurbishments us to demonstrate the full benefits of Bruderer precision high and overhauls speed presses for you and indeed your customers. Feel free to contact us with any questions.

BRUDERER UK LTD, Cradock Road, Luton LU4 0JF Connect with us across Social Media Tel: 01582 560300 | Email: [email protected] www.bruderer.co.uk @Brudereruk Special Report Providing you with 3 Presses in 1

The BPG 22 planetary gearbox developed by customer with real added value. A planetary BRUDERER is a world first, and something that gearbox that is built into the shaft of the main experts and tool-makers have been motor of a fully-automated stamping press waiting for – for a long time. It is an additional enables test runs to be carried out, steered by gearbox which will enable fully-automated manual control, at the lowest stroke rate and High-speed precision BRUDERER BSTA 510 at full press tonnage. In essence the machine stamping presses to be turned into test can be run from as little as 1 spm or micron machines for trying out new tools of speeds increments through BDC (bottom Dead centre) at less than I stroke per min controlled an at full tonnage of the machine in this case increment at a time, and at a flick of a switch 50 tons. return to full production from 100spm to The findings that are produced can then be 1500spm – creating incredible added value for carried over exactly and used in the regular customers! production process. The advantages for customers are manifested in: • increased efficiency • reduced costs • less space required • simple handling and more flexible work processes such as forming etc • There is also a gain in terms of logistics, since tools have to be transported less often

The catalyst for this development was the servo press In the past, stamping/manuafcturing companies technology which who designed and made their own press tools has become far in-house had only one solution for these very more prevalent in different tasks – they had stamping presses for recent years on other machine types. actual production whilst having to carry out tool and stamping tests on a separate machine, While it is of little or no use for stamping at which would then as a rule stand idle until the high stroke rates, which is one of BRUDERER’s next series of tests, taking up valuable capital core competencies, it is however very suitable and production space. for slower processes such as test stamping and try-out of tools. BRUDERER therefore decided THREE BECOMES ONE to use these very properties and adapt them This new development from BRUDERER now to their high-performance fully-automated offers a practical alternative which provides the stamping presses, and the result is the BPG 22.

28 The aim was to combine three machines in one able to work – namely to take a regular high-performance slowly but at fully-automated stamping press and equip it high strength at very low stroke rates with the capabilities and this ended of a test press, which however do not have up creating any influence on the (day-to-day) functioning various new at higher stroke rates. A particular challenge functionalities. was making the strength and torque which BRUDERER and the relevant suppliers were also are required for comprehensive test settings involved on the hardware side, and whereas available without the need for a significantly »speed at all costs« used to be the watchword, larger electric motor or having to changing now it is more a case of »slower but stronger«. something significant to the basic principles Consequently, everybody involved in the BPG of the tried and trusted BRUDERER stamping 22 project has come to see the BRUDERER press. stamping press in a new, previously unseen light. ALL DIFFERENT, ALL NEW The project team found The result of themselves confronted this teamwork with quite a task. It was is a three-level not merely a case of planetary developing a planetary gearbox with gearbox – it had to be a ratio of a three-level version. The basic concept also approximately called for it to be enclosed in a rotating casing, 1:19. The real heart of the BPG 22 is the which posed a further challenge for project software and the manual control for the manager Pascal Hardmeier and the rest of his machine. The main functionalities include team. the switching on and off of the gearbox in After the gearbox had been constructed test mode, movement of the machine and mechanically, it was time to focus on the adjustment of the ram height all via manual development of the software, and this proved control, as well as production at low stroke to be an exciting challenge for Engineering, rates. The data that is generated can then be and Sven Kächelin, in charge of the relevant transferred to the tool data memory of the software development. This was a project where machine’s control system. production at low speed was the main priority EVERYTHING IN HAND as opposed to stamping, and this meant that The manual control enables the speed of the everyone involved had to approach the project ram movement to be adjusted to different from a completely different point of view. levels. Maximum press capacity and the highest The work on the BPG 22 also provided new torque levels can also be set and recorded. insights of a more general nature, for example The machine operator can thus start the top and in terms of process monitoring or the behaviour bottom dead centre individually and move the of BRUDERER fully-automated stamping presses ram to precisions of a hundredth of a millimetre. at low stroke rates. What Herbert Högger found The manual control can activate and control most impressive is the fact that the complete the functions that are required for test mode. tonnage of the machine is literally in the hands This for example means that the ram and the of the machine operator. Kächelin found the upper part of the tool can be moved extremely development of the manual control particularly slowly onto the lower part, imitating a stamping demanding. The requirement was for it to be process and testing move slowly forwards or > Providing you with 3 Presses in 1

backwards in fixed geometrical increments or by material is able to flow progressively. regulated shifting using pre-set values. Therefore, the approach from top dead centre to a given position can be up to speed of say Backwards movement can be implemented 100spm and then through bottom dead centre depending on the tool, and the permitted press at say 10spm and return top thereafter at capacity can be changed where necessary. 90spm. The operator can also specify breakoff criteria for continuation or return stroke in the control The BPG 22 has no negative effects on the system. regular stamping process. On the BSTA 510 when it is in stamping mode, the usual stroke The manual control has several different rates of between 100 and approximately 1100 indications. A multi-coloured display shows the strokes per minute, depending on the machine maximum and current press capacity, the press size, are still possible. The BPG 22 also has no angle in degrees and the distance of the ram effect on the footprint of the machine – the from the lower dead centre. The control also planetary gearbox is fitted in a way that the enables error messages from the machine to stamping press needs no extra floor space to be displayed and acknowledged. It is linked to accommodate it, which is another advantage the machine by a pluggable cable and can be compared with previous solutions which used in front of or behind the fully-automated required separate equipment for test and stamping press, with the necessary cable production functions. connections built in on both sides. If the manual control is not required, it can be stored in the The new planetary gearbox option is available wall mounting that is delivered as standard or from 28-ton machines up to 160-ton machines, attached by means of a magnet to a place of with three different die bed lengths of 950mm the operator’s choice around the machine. to 2.2 meters.

FUNCTIONAL AND PRACTICAL The conclusion is the customer will have a very The press has the ability to be programmed efficient and versatile high-speed precision in every press operation you would require press, justification for Capital investment is and act like a servo press, especially for doing three-fold for the cost of only one machine, forming work with component parts where its representing excellent value for money, residual critical to slow the stamping process down value would be increased due to the versatility through bottom dead centre, to help with small of such a machine. drawn parts or critically formed areas where the

30 Examples below of products/applications that can be produced on a Bruderer press with the BPG.

All produced on one machine, with accuracy to less than 1 micron. For more information on the BRUDERER BPG, or any other aspect of our machines, please contact one of our dedicated sales team. BRUDERER UK LTD, Luton. T. 01582 560300 E. [email protected] W. bruderer.co.uk

Calling Young Members! Take control of your future! The Institute of Sheet Metal Engineering is including promoting the event on social media, recruiting new members onto our committee to contacting collages and reaching out to sheet represent the growing number of apprentices metalworking companies to spread the word wishing to become actively involved in shaping about the competition. and developing the future of sheet metal forming in the UK. You will be invited to committee meetings, which you can join in person or via Skype or As a member of the committee you will be part telephone. of the active community who work to recognise, reward and promote the world-class skills of UK We are looking for current apprentices and also sheet metal working apprentices. those that have recently finished their training.

You will contribute to organising and If you have questions or would like to put your promoting this year’s Skills Competition, name forward please contact us at an event that has been running for 50 years, [email protected] THE POWER TO IMPRESS

Specialists in Mechanical Power Press Repairs, Spares, Inspection & Upgrades Est. 1980 - MPPS boasts a dedicated and skilled team of experienced engineers providing comprehensive support and service to the Power Press, Metalworking and allied industries.

Core Services

• Site Service • Hydraulic Presses • Spare Parts • Machine Relocation • Power Press Inspections • Electrical & Control Systems • Machine Refurbishment • Sub-contract Machining & Upgrades

MPPS, 34 High Street, Princes End, Tipton, Dudley DY4 9HP 0121 520 4320 / [email protected] / www.mpps.co.uk