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Driving Investment Automotive.qxd 25/4/07 9:32 am Page 49 AUTOMOTIVE Driving investment While the aerospace sector may have grabbed the headlines over the past two years, the UK’s automotive industry remains hugely influential in the country’s economy, as Steed Webzell reveals lthough Heller now supplies trust,” says the company’s managing Ahorizontal machining centres to a director, Tim Allen. “From the outset wide range of industries throughout the Heller has given us excellent assistance, world, its roots remain in the automotive developing the production process, Above: FSG delivered a businesses that are local to it – Daimler recommending manufacturing globally competitive moulded part price for Chrysler, Audi and VW. The company techniques and designing the fixtures to Harman Becker. Below, BM Injection has grown with the needs of this give us the best and most versatile brought wire-cut EDM in-house and saved industry, developing its machines and machining system.” money and boosted its automotive mould services to suit the sector’s ever-changing Heller’s expertise in the automotive tool tool technology demands. sector is reinforced by its client list. Other Manufactured at the company’s notable UK installations include Mahle company doesn’t know about the plant in Redditch, Heller horizontal Powertrain at Wellingborough, and automotive industry, and it provides a machining centres are today a feature at Perkins Stafford, where two new Heller second-to-none engineering support OEMs as well as at first and second tier MCH 250 machining centres are working service.” suppliers across the UK’s automotive on cylinder heads alongside an existing While diesel engines are a gaining a industry. For instance, the all-wheel- three-machine Heller con-rod cell. following with the motoring public, drive system for the new Ford Transit will development and production be produced by MJ Allen at its own ALL IN A STANDARD WEEK engineering effort is also being applied foundry and machine shop in Ashford, Senior manufacturing engineer Mark to direct injection petrol engines. They Kent, using a Heller MCi 16 horizontal Johnson, who headed the Six Sigma are now able to provide up to a 20 per machining centre. Green Belt team in charge of the project, cent improvement in economy over “We wanted a machine tool supplier says: “With 85 per cent efficiency, which conventional engines, giving motorists who would give us time and we knew from experience we would another cost-effective alternative. understanding, and in whose expertise achieve on the Heller machines, we could As Markus Schnyder, managing and engineering capability we could meet the production requirement within director of Mikron Machining a standard five-day week.” Technology based in Agno, Switzerland, Further down the supply chain, maintains: “Fuel injection for both diesel Stroud-based sub-contractor Springfield and petrol engines is a very demanding Engineering provides precision volume technology sector. The associated design parts to a host of demanding customers, and development, as well as machining, including those in the automotive sector. constantly push the boundaries of The company has recently won an production engineering knowledge to order for the volume production of meet ever-tightening legislation.” And he diesel engine cylinder heads from one of should know – because he heads up the the leading German manufacturers – its Mikron operation that has become first major contract for an overseas expert in the supply of machining automotive OEM. “Heller was the technology to the fuel injection business. obvious choice,” says company founder Mikron Machining Technology, with Eddie Reed, explaining the installation of a third of its machine tool sales in fuel an MCH 250. “There is nothing the injection, is at the forefront of these www.machinery.co.uk ● May 2007 49 Automotive.qxd 25/4/07 9:33 am Page 50 AUTOMOTIVE rapidly developing levels of sophistication but, unlike other machine tool suppliers, it is able to combine both machine tool and tooling expertise, through its sister company, Mikron Tool. This provides the ability to develop cutting tools such as drills, endmills and form tools in conjunction with the application engineering and machine tool build teams. Typical applications include an extremely tough 50 MnCrV4 forged steel truck injector and, such is the application engineering and machine build quality, that a 3.56 mm diameter hole with a tolerance of ±0.05 mm has been drilled 78 mm deep, (a 22:1 depth to diameter ratio) using a Mikron CrazyDrill in 20 sec. Starting with a pilot drill to enable bushless drilling at 6,000 rpm and 0.04 mm/rev feedrate, penetration was 254 mm/min over a depth of 6.3 mm. The tool was then changed to a Mikron CrazyDrill of the same size to finally drill to depth at 9,094 rpm at 0.025 mm/rev feedrate (227 mm/min penetration rate). In fuel injection applications, holes as small as 1.7 mm diameter are drilled with high pressure, 120 bar fully programmable through-tool coolant. ANOTHER MIKRON The demand for UK manufacturing input into mouldmaking, toolmaking, pattern making and rapid prototyping for the automotive sector is driving reinvigorated investment in machine tools and machining services. For example, Brackley-based Frazero, A single Index V160C hanging-spindle VTL and innovative tooling from Geo Kingsbury an international automotive interior provided capacity at half the alternative solution’s price for one automotive sub-contractor design and manufacturing specialist, has recently invested in a Mikron XSM 600U times from two hours to 20 minutes for our injection mould tooling makes us 5-axis machining centre from Agie a glove compartment-housed cigar case. feel more in control when building tool Charmilles. Investment is all about generating manufacture into estimates,” explains The Frazero operation focuses on savings. Providing injection mouldings general manager Tim Combes. “As well providing conceptual solutions through and injection mould tooling to all of the as saving outsource costs, the new to production of complete car interiors – UK’s main tier 1, 2 and 3 automotive machine has improved our ability to up to 3,000 a year. Customers include suppliers is a competitive business, produce cutting edge tools.” Bentley, Bugatti, Cadillac, Ford, Jaguar which is why Hampshire-based BM Many UK toolmaking companies Lincoln, Morgan, Nissan and Rolls-Royce. Injection decided to take control of its with the right levels of expertise are The investment in the Mikron XSM wire erosion processes, purchasing a new reporting increased orders from the 600U provides Frazero with ultra-fast Sodick AQ325L with linear drive automotive sector. Take Glamorgan- machining capability and, as a technology from Sodi-Tech EDM. based FSG Tool & Die for example, which consequence, has reduced part cycle “Having an in-house wire facility for has just won an order from the May 2007 ● www.machinery.co.uk 50 Automotive.qxd 25/4/07 9:34 am Page 52 AUTOMOTIVE tools that are the “finished article”, and do not need nipping-off sprues. Motor industry facts When a UK automotive sub- contractor won the contract to supply According to the latest figures (2005) from the Society of Motor Manufacturers fuel injection pump adapters for a new and Traders, the UK produces just fewer than 1.6 million cars annually (around diesel engine, the company decided that 400,000 for the home market). The UK still has car manufacturing sites owned by: a dedicated cell was required to machine Aston Martin (Gaydon and Newport Pagnell); Bentley (Crewe); BMW-Mini the high pressure aluminium die castings (Oxford); Honda (Swindon); Jaguar (Halewood and Birmingham); Land Rover on both ends within a 76-sec TAKT time. (Solihull); Lotus (Norwich); LTI (Coventry); Metrocab (Tamworth); Morgan The obvious choices were to install four (Malvern); Nissan (Sunderland); Rolls-Royce (Goodwood); Toyota (Burnaston); 3-axis horizontal spindle lathes and and Vauxhall (Ellesmere Port). The top five plants in terms of annual volume are employ two operators, or to invest in two Sunderland (315,000), Burnaston (264,000), Oxford (200,000), Ellesmere Port opposed-spindle turning centres. (189,000) and Swindon (186,000). However, Geo Kingsbury Machine The UK currently manufactures just under 207,000 commercial vehicles a Tools came up with an alternative at year. Plants include: Alexander Dennis (Guildford); Dennis Eagle (Warwick); Ford around half the capital cost, based on a (Southampton); IBC (Luton); Land Rover (Solihull); LDV (Birmingham); Leyland turnkey cell with a single Index V160C Trucks (Leyland); Optare (Leeds); and Peugeot (Ryton). hanging-spindle lathe. The UK also produces around 3.1 million engines a year (incuding non- Key to achieving this cost-effective automotive), which has climbed from 2.4 million in 1999. solution was the ability to machine the adapter in one clamping, rather than two, using a bespoke two-jaw chuck that automotive division (Harman Becker) of Elsewhere, hot runner tools from allows sufficient clearance at the back Harman International to help develop an DMS-Diemould proved to be the for the component to be turned on the “aluminium cone” in-car speaker system. solution when Wolverhampton-based reverse end using a special tool that is The challenge was to develop a mass Fern Plastic Products secured an order to able to access the back face through the production manufacturing process, at a supply injection mould tooling for diesel bore of the component. Not only is one competitive price, and create a product engine filter components. machine sufficient, but the 54-second appealing to the top-end automotive “The six-tool order featured fully cycle is well within the TAKT time of the market. The task for the toolmaker was automatic unscrewing technology and line, which includes assembling an O- to develop tooling methodology that was fairly complex in its build-up,” ring on to the adapter and pressure could cope with very thin section explains Fern Plastic’s works director, testing prior to just-in-time delivery to components and assemblies in a variety Keith Harper.
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