p18 p22 March 2021 March MACH 2022 preview week on the rise Growing presence Technology insights Metalforming association MachineryTweets MachineryTweets | MachineryMagazine MachineryMagazine | p31
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UK DECARBONISING ENERGY PROJECT UTILISES INNOVATIVE ELECTRIC MACHINE TECHNOLOGY UK DECARBONISING ENERGY PROJECT UTILISES INNOVATIVE DMG Mori Digital Open House news
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Volume 179 Number 4304 March 2021 CONTENTS
Regular sections 10 Lead feature Stablising the grid 10 A project utilising electric machine technology to stabilise the National 7 Comment Grid and increase the amount of renewable energy on the electricity system has been launched. Justin Burns investigates News round-up 8 Vargus Tooling Ltd expands 14 Supply side DMG Mori digital open house team by employing two more DMG Mori’s Open House in Pfronten, Bavaria, Germany, is a major event 8 Starrag UK offering new for the company, but due to the Covid-19 pandemic, it was held online gantry mill range this year, where the machine tool manufacturer revealed three new 8 ETG signs partnership with world premiers
Winbro Group Technologies eld Forgemasters Shef Cover image: 8 XYZ Machine Tools 18 Exhibition preview MACH 2022 digital preview week appoints Chris Hellier Last year’s biennial MACH show was cancelled due to Covid-19 and has 14 8 Gigafactory set to be built been rearranged for April 2022. The MTA, organiser of the event, held a in Coventry digital preview week featuring various seminars highlighting innovative new 8 Fintek appointed UK agent projects and technological developments for Rena Technologies 9 HV Wooding invests in high 22 Metal forming Growing presence speed press machine The MMMA is growing its membership despite a dif cult period due to 9 EMAG Group acquires the Covid-19 pandemic and will showcase everything it offers in its Samputensili Machine Tools largest ever Metalworking Village at MACH 2022 next April 18 9 UK government launches new research agency 25 Heavy engineering Devon delight 9 IFR report nds robot Heavy engineering is a competitive sector, but Devon-based Blackhill density low in the UK Engineering has won a major contract and is looking to grow business 9 Gordon Murray Group gets even further in 2021 go ahead to build new HQ 9 LISI Aerospace and AMRC 26 CADCAM & production IT Boosting bottom lines secure funding from ATI Petford Tools uses four Hexagon packages to overcome challenges; 22 Radan software helps Trio Metall diversity its business; Multax New products Engineered Precision Ltd is boosted by investment in CAM software from 9 Ceratizit’s new clamp Open Mind; plus, news and products in brief 9 Trumpf extends range 9 Greenleaf new line 31 Tooling Getting to grips with chips 9 Sick expands portfolio Most production engineers agree that any machined part is only as good 9 Festo online tool as the cutting tools deployed. Steed Webzell rounds up the latest 9 Ceratizit adds chuck range manufacturers to gain from new tooling investment 31 9 Kerf’s new plasma machine 9 Fanuc widens robot offering 34 Grinding, honing & surface fi nishing Machine moves 9 Chiron machining centre Ondrives adds a second Studer cylindrical grinding machine to meet 9 LK Metrology upgrades demand; Marlor buys Rollomatic Shapesmart as it moves into the medical sector; Danish tool manufacturer puts trust in Vollmer; plus, 48 Classifi ed section news and products in brief 50 This month 25 years ago... 38 EDM & ECM Investment plans spark into life 34 A number of notable recent installations are demonstrating the enduring
Information Society Initiative launched; Centreline Machine Tool Company relocates from Hinckley to Nuneaton; RCS introduces a new punch press module for appeal of wire EDM, which has much to offer OEMs, subcontractors and customised hole punching and notching machine; and benefi ts of the Internet
25years ago march1996 toolmakers alike. Steed Webzell has the details
on choosing the right punch press tooling package. n the rst issue of March, our comment piece discusses the launch We also have two turning features, reporting how higher than of the Information Society Initiative by the Department of Trade and expected demand for a new product prompted radiation Industry (DTi) to promote the bene cial use and development of I thermometry Land Infrared to look for ways of combing machining information and communications technologies’. We ask whether those operations; no-frills, two-axis, turning-only CNC lathes still account charged with driving the society appreciate how long electronic data for the majority of machines sold; and a feature on grinding, with has controlled the world of engineering manufacture, as since the the impending launch by Swiss-based Mägerle of a new space- 40 Mazak Medical capabilities dawn of numerical control, considerable expertise in the handling of ef cient creep-feed grinding machine, specially designed for electronic data has built up – and now controls the machines to the processing small parts. extend that robots, milling machines and CMMs can perform In the second issue of March 1996, as the biennial MACH operations more quickly. We conclude, UK engineering businesses can machine tool show draws closer, the UK’s investment record is learn and capitalise from commercial areas of the society and urge under attack by the Labour Party, as it says manufacturing companies to join as membership would bring bene ts. investment fell during the last quarter of 1995, hitting a level only In news, multi-head and tooling manufacturer Centreline seven per cent higher than during the depths of the recession. Machine Tool Company relocates from Hinckley to a new factory However, we note to get an accurate picture you must separate and headquarters in Nuneaton, coinciding with the start of plant and equipment and recent gures show the UK’s 42 Composites machining Cutting times company’s 25th anniversary; Toolroom Technology of Aylesbury is consumption of machine tools was up strongly. appointed as UK reseller for model-maker desktop prototyping In news, the three machines in Colchester’s Tornado CNC lathe system from US-based Sanders Prototype; Seco Tools of Alcester range are re-christened ‘Storm’ for the North American market; now has pages on the Internet; subcontractor Laser Process Velden Engineering UK purchases a Daewoo Puma 10HC CNC lathe A Czech Republic collaboration has developed a new hybrid metal and 45 places an order with Newall Aerospace for a laser cutting system; and Daewoo ACE V50 vertical machining centre from Mills and machine management specialist Wealdown Integrated Systems Manufacturing Technology of Norwich; RCS (Tooling Systems) Ltd develops a new machine to cut the time-consuming and costly introduces a new punch press module for a customised hole practice of transferring sawn off components to a nishing machine punching and notching machine; and there is a UK debut for the by integrating sawing and machining operations into one unit. carbon bre composite milling cutting disk utilising a Doosan machining rst Hitachi Seiki TF20 high speed compact turning centre to be
NJ /stock.adobe.com /stock.adobe.com NJ In feature articles, our main lead is on punch presses, on sold in the UK, to G.D Cocker & Son of Lytham St Annes. why more attention is not paid to the choice of In feature articles, our technology focus is on the Internet, and tooling, when the cost will be greater over the how the “communications system” can put businesses in touch lifetime of a punch press than the with the world; we look at the advances in CMM technology which centre machine itself. Eric Roberts, technical director of tool are meeting the challenge of higher productivity rates and tighter manufacturer Wilson Tool component accuracy; nd out about Fidia’s new package that International, notes there optimises utilisation and operators’ skills; and have the rst of are signi cant productivity three MACH ’96 previews, looking at new developments the and economic bene ts machine tool industry will be offering visitors. ■ ▼ ▼ ▼ ▼ The EU’s Veterinarian Sri Lanka beat ▼ Mike Tyson TKOs Committee bans the Australia by The Hubble Space Frank Bruno in export of British beef 7 wickets to Telescope the 3rd round due to “mad cow 50,000 swimmers raise £15m 43 Cutting oils & coolants Quality control win the 1996 photographs the to gain the world Sara- for charity during disease” (BSE) Cricket World Cup
rst surface heavyweight jevo BT’s Swimathon
Maridav/stock.adobe.com Maridav/stock.adobe.com Maridav/stock.adobe.com Maridav/stock.adobe.com Maridav/stock.adobe.com
Daniel Meunier /stock.adobe.com /stock.adobe.com /stock.adobe.com /stock.adobe.com Meunier Meunier Meunier Daniel Daniel Daniel in Pakistan /stock.adobe.com Meunier Daniel photos of Pluto /stock.adobe.com Brugger Carl
Elnur /stock.adobe.com /stock.adobe.com Elnur title mar 96 mar Key Events Key Investment in Rocol cutting uid solutions proving bene cial to Brown & Holmes; plus, news and products in brief The coatings for the highest performance
For more information: cutting.tools/en/dragonskin 45 Medical sector Global solutions 50
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050_25yrpages_MACH_MAR21 new.indd 50
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 5 Precision gear measurement Production quality is of fundamental importance in the manufacturing of precision gears. Mitutoyo understand these challenges and are trusted to provide the best solutions for inspection by many leading brands. With extensive knowledge and experience of gear measurement, and by utilising the latest CMM, Vision, Form machines and dedicated software, Mitutoyo are an ideal partner to meet your exacting quality standards.
To discover more about the effective and reliable evaluation of gears visit www.mitutoyo.co.uk/gears or scan the code below: COMMENT Justin Burns, Editor
Editor: Justin Burns [email protected] Powering On Art editor: Neil Young Sales director: Joe Opitz The UK’s energy mix is seeing significant growth in renewable [email protected] M: 07967 169098 generation and data for 2020 has shown it was record-breaking year for clean energy, as we rely less on fossil fuels than ever before. Publishing assistant: Lyn Evola [email protected] Our cover lead (page 10) delves into a new decarbonising energy
Circulation manager: Chris Jones project that has been launched, which will manage stability on the [email protected] grid, helping increase the amount of renewable energy transmitted Production: Chloe Jeakins on the UK electricity system and prevent power blackouts. [email protected] Keith Greener Grid Park, in Moray, Scotland will utilise innovative new rotating Publisher: Jon Benson machine technology manufactured by GE Power Conversion, while steel casting and [email protected] forging specialist Sheffield Forgemasters is also playing a key role in ensuring the Annual subscription: £118 (UK) and £173 (Overseas). energy project powers on. On a different note, the last 12 months have been challenging for the entire machine tools industry, whether you are a major or minor player, although the big guns have on the whole been able to better navigate the crisis. In this issue, we report on the DMG Mori Open House (page 14) that was held digitally this year, where the Japanese-German global machine tool maker announced three new global premiers to the marketplace. The Covid-19 pandemic has impacted every aspect of business, especially events, www.markallengroup.com but the creativity of organisers has been inspiring to see. The Manufacturing
Machinery (incorporating Technologies Association (MTA), the organiser of MACH 2020, has rescheduled the Sheet Metal Industries) event to April 2022, but held a digital preview week with insightful seminars on the Machinery is published on the first Friday of every month by MA Business, Hawley Mill, latest technological developments and we report (page 18) on some of the interesting Hawley Road, Dartford, Kent DA2 7TJ T: 01322 221144 F: 01322 221188 discussions that were had. E: [email protected] Aside from the content in this issue, as part of the evolution of any publication, it is W: www.machinery.co.uk important to freshen editorial and introduce new features, but to ensure everything If you change jobs or your company moves to a new location, please contact circulation@markallengroup. com to continue receiving your free copy of Machinery. that has been so successful in the past is retained.
© 2021. All rights reserved. No part of Machinery From next month, we will launch the ‘Machinery Interview’, where each month we may be reproduced or transmitted in any form, by any means, electronic or mechanical, including will speak to a top-level decision-maker at the heart of the machine tools industry and photocopying, recording or any information storage or retrieval system, without permission in writing from production engineering. the publisher. Please read our privacy policy, by visiting http:// You will also notice a change in the digital edition for this issue of Machinery, as it privacypolicy.markallengroup.com. This will explain how we process, use & safeguard your data is the first to be published on the innovative new BlueToad platform, giving readers a The views expressed do not necessarily represent those of the editor or Machinery. Advertisements in the journal do not imply endorsement of the products or vastly enhanced and improved user experience. services advertised. The platform enables not only easier-than-ever access to digital replicas of all the Print – ISSN 1753-0482 Online – ISSN 2049-3312 print magazine pages, but it also includes an enhanced Smart View that optimises all Printed by: Pensord Press, in the UK content for mobile devices, so you can access the latest edition wherever you are and on whatever device. Enjoy reading the issue. ■ www.machinery.co.uk
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 7 DAILY NEWS & PRODUCT UPDATES @ www.machinery.co.uk
News round-up Automotive sector set for welcome boost Vargus Tooling Ltd – a developer, A new ‘gigafactory’ to manufacture manufacturer and supplier of electric car batteries is set to be precision threading, grooving, turning built in Coventry, with Coventry and hand deburring tools – has Airport identi ed as a possible site expanded its team, appointing two for the development. new staff members. Coventry City Council intends to www.is.gd/UGAk7Q secure pre-emptive planning permission for a “gigafactory” The global machine tools market beside the city’s airport, in a move will reach revenues of around that could create 4,000 jobs. $122bn (£87bn) by 2026 and grow A joint venture (JV) between the at a compound annual growth rate council and Regional City Airports A gigafactory in the West Midlands (CAGR) of 8.5% from 2020-26, will seek outline planning would boost the automotive sector according to a new report by Arizton permission by the end of 2021 in Advisory & Intelligence. the hope of attracting an commentators believe the West key goal to keep automotive jobs, www.is.gd/cP9tTT experienced manufacturer to start Midlands will require a battery as the sector is moving away from production by 2025. plant to supply manufacturers such the internal combustion engine and Starrag UK is offering potential The JV partners will develop as Jaguar Land Rover, Aston Martin has set a £500m funding pot to customers of gantry mills a new proposals and submit an outline Lagonda and BMW, who all have support the electri cation of range of machines by planning application for a production facilities in the region. vehicles, including developing complementing its Starrag Group gigafactory in 2021. This will take If the development takes place, gigafactories across the UK. Droop+Rein brand with the machine place alongside talks with battery it would be a huge boost for the BritishVolt is building the rst portfolio built in Australia by H & H suppliers and automotive automotive sector in the UK and UK battery factory in Blyth, Machine Tools. manufacturers to secure the long- West Midlands. Northumberland. Construction is www.is.gd/FFbIsd term investment needed. The government has identi ed set to begin in the summer and it Automotive industry investment in battery factories as a is part of a £2.6bn investment. The Japanese-German injection moulding machine manufacturer Sumitomo (SHI) Demag will be 19 pandemic, but an online event Research Centre (AMRC) with an printers and solutions. serving the Czech and Slovakian will take place from 15-20 March. agreement that will continue two www.is.gd/QjUNOM markets from 1 April, 2021. www.is.gd/02bWB7 decades of innovation and www.is.gd/1wVGyO collaboration for another ve years. XYZ Machine Tools has appointed Collaborative robot (cobot) www.is.gd/JF7dVT Chris Hellier as commercial The Engineering Technology Group specialist Reeco Automation has manager. He has spent his career (ETG) has signed a technology started construction on an expansion The University of Wolverhampton’s specialising in manufacturing. partnership with machine tool of its premises to meet growing Additive Manufacturing www.is.gd/TEkloI manufacturer Winbro Group demand of customers in the UK and Functional Materials Technologies. Internationally. research group has Metal component www.is.gd/fPzzsF www.is.gd/hLEs0z developed an surface nishing antiviral specialist Fintek The organiser of the Taipei Aerospace giant Boeing has material made has become International Machine Tool Show renewed its longstanding from copper, exclusive UK agents (TIMTOS) 2021 has postponed the relationship with the University of silver and for Rena physical exhibition due to the Covid- Shef eld Advanced Manufacturing tungsten that Chris Hellier has joined Technologies Austria can be 3D XYZ Machine Tools GmbH H-series range GM CNC Ltd has disrupted the market since becoming the UK’s printed and kills of machines that use exclusive dealer for Victor machine tools and the Oldham-based family Covid-19. their patented Hirtisation run business has appointed Joe Bricknell as the new area sales www.is.gd/wCN0iK process for nishing of 3D printed representative to bolster the sales operation for this popular brand of metal parts. machine tools. Additive manufacturing (AM) www.is.gd/GsdAYA Joining the company just before the turn of the year, he will be machine giant Stratasys - responsible for growing sales of the Victor brand of machine tools that are represented by Derbyshire-based The Manufacturing Technology well established in the UK. SYS Systems – has acquired UK- Centre (MTC) is to trial a purpose- www.is.gd/2htXk5 based RP Support Ltd, a provider of built private 5G network. industrial stereolithography 3D www.is.gd/qZbIgo
8 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets NEWS
Gordon Murray Group – an automotive design, engineering and Product pick 10 manufacturing business – has had a planning application approved to Precision clamping build a new global headquarters Ceratizit has launched the WNT and technology campus in Surrey. X5G-Z – a new, efficient, and highly www.is.gd/PKJ5QT precise, clamping system for machining centres. A new report by Fein has found www.is.gd/lbg06O 80% of metalworkers believe not Kent-based subcontract enough is being done to encourage New TruLaser models manufacturing specialist HV young people to take up a career in Trumpf has introduced two new Wooding has invested over the sector. The UK metalworking models to its TruLaser Tube range. £120,000 into new tooling and the industry is struggling to attract new The TruLaser Tube 3000 and the TruLaser Tube 5000 are aimed aimed at those installation of a Bruderer BSTA 25H. talent and apprentices. new to the technology or needing to boost capacity. The high speed press machine has www.is.gd/TwuRtk www.is.gd/7VAvDP helped deliver an aerospace contract that has been reshored from Spain. A team of apprentices at the Solid ceramic end mill range www.is.gd/g108s5 Advanced Manufacturing Training The Greenleaf Corporation has launched the XSYTIN-360 – a new line of high Centre (AMTC) has redesigned a performance solid ceramic end mills – to the global market. www.is.gd/XQiYCB The German-based EMAG Group DIY hydraulic arm kit so an has acquired Italian firm educational charity can continue to Safety controller portfolio widened Samputensili Machine Tools and reach school children despite Covid- Sick has added the Flexi Compact to its portfolio of safety controllers, featuring a Samputensili CLC – which employs 19 restrictions. modular, compact and scalable design that focuses on space saving, responsive 87 employees across two sites near www.is.gd/9Yr6Ic performance and ease of use. www.is.gd/ifiwaq Bologna and Reggio Emilia, Italy. www.is.gd/sit9gs Quicker and easier configuration tool by Festo Industrial automation specialist Festo has introduced a new online configuration The UK government has tool that makes it easier and quicker to select the correct valve or actuator of a launched the Advanced process application. www.is.gd/9AIyZ8 Research & Invention Agency (ARIA) that will be led by Fresh hydraulic chuck range scientists who will have the freedom Ceratizit Group’s Team Cutting Tools has launched new variants of its hydraulic to identify and fund transformational chuck range with VDI and cylindrical shank connections as part of the WNT science and technology at speed. Performance range of tooling. www.is.gd/Ao63y4 www.is.gd/k24tG8 Plasma machine hits the market The International Federation of Kerf Developments has launched a new Linc-Cut S 1530W plasma machine that it Robotics (IFR) says the average LISI Aerospace (BAI UK) and the says is cost-effective, easy to install, set up and operate. www.is.gd/hJUJyb robot density in the global University of Sheffield Advanced manufacturing industry hit a new Manufacturing Research Centre Strongest SCARA to date from Fanuc record of 113 units per 10,000 (AMRC) have jointly secured Fanuc has expanded its SCARA robot line-up with the introduction of the newest employees in 2019. £975,000 in funding from the model: the SR-20iA – able to carry payloads of up to 20kg, and it is the company’s However, the UK lags behind the rest Aerospace Technology Institute (ATI) strongest SCARA to date. www.is.gd/HKeF24 of the world, ranking 24th globally to unlock productivity gains, new with 89 units per 10,000 in 2019 markets and reduce waste in the New machining centre launched by Chiron with a total of 21,700 in operation. fastener industry. Chiron has launched its latest machining centre, the new 5-axis Chiron www.is.gd/xcgwv0 www.is.gd/ymUWQg DZ22W (pictured left). Based upon the proven platform of the existing 16 Series, the DZ22W is available in the UK from the Engineering XYZ Machine Tools has created an Bolton-based Technology Group (ETG). www.is.gd/5hGmf8 automation and machine package Heatrod Industrial that will provide a cost-effective has acquired CMM upgrades from LK Metrology route to maximising productivity. The GrayBar Ltd - a UK-based coordinate measuring machine (CMM) manufacturer package revolves around the three specialist LK Metrology has designed a new, more efficient air bearing and machine LR series of XYZ vertical manufacturer of carrier which are now being fitted as standard to its ALTERAC machining centres, the XYZ 500 LR, products for the rail range of ceramic-bridge, multi-sensor CMMs. www.is.gd/5naspi XYZ 750 LR and XYZ 1000 LR. industry. www.is.gd/yYeDJk www.is.gd/stujtX
www.machinery.co.uk | MachineryMagazine | @MachineryTweets |March 2021 9 A project utilising electric machine technology to stabilise the National Grid and increase the amount of renewable energy on the electricity system has been launched. Justin Burns investigates
Decarbonising UK energy
Pictured above: A n innovative decarbonising energy project that will casting and forging specialist Shef eld Forgemasters ( www. render of the GE help increase the amount of renewable energy is.gd/8JDcOd ), which is manufacturing the key component of rotating stabiliser Atransmitted on the UK electricity system and prevent the main rotator shaft and hub. machine to be power blackouts, is taking shape and on target to be Other contracts have been awarded. Powersystems UK used in Keith operational later this year. with civil subcontractor Knights Brown will undertake the The new approach to managing the stability on the electrical and civil engineering works for the £20m venture, National Grid, will see the rst project taking place at Keith while AECOM has been appointed Owner’s Engineer. Greener Grid Park, in Moray, Scotland, located near the Statkraft was awarded the stability contract in January Scottish and Southern Electricity Networks transmission 2020 as part of National Grid’s Stability Path nder Project substation at Keith. It is part of the Greener Grid Park being to meet its ambition, that by 2025, the electricity system led by hydropower and renewable energy specialist can be operated at zero carbon. The contract provides grid Statkraft ( www.is.gd/EKl01q ). stability services when there are no fossil fuel generators At the heart of the Keith project are installations of two on the system to provide this. large rotating stabiliser synchronous machines There will be an increased demand for this service as manufactured by GE Power Conversion ( www.is.gd/Bn8FDV ) the amount of renewable energy generated increases and at its Rugby site – designed to provide stable ows of the two machines at Keith are well on course to be up and energy through the grid network. These large machines running in autumn this year. with built-in ywheels replace the spinning turbines of a The Greener Grid Park is a pioneering project to help traditional power station, but without emitting any carbon achieve zero carbon emissions. Keeping the power network dioxide. stable has become more challenging as more renewable Other companies in the supply chain are also making energy is generated. This has meant National Grid has, at the Keith grid stability project a reality, including steel times, been forced to shut down wind farms and run gas
10 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets LEAD FEATURE STABILISING THE GRID
power stations even when there is more than enough of a blue whale” – so somewhere around 100 tonnes. Below: The BOST renewable energy to meet demand on the UK grid, to keep Construction of the rotating stabilisers is designed for fi ve-axis vertical turning lathe the system stable. easy disassembly, reassembly and servicing on site; (VTL) being used Statkraft will manage the construction and operation of however, the factory build requires a lot of time-served skill at Sheffi eld the project and head of grid integration Guy Nicholson, that is the core of GE Power Conversion’s rotating Forgemasters explains the grid network needs to keep up with the rapid machines plant in Rugby. This includes the intricate progress renewables has made in the UK and projects like process of winding the stator, the stator core construction Bottom: Sheffi eld Keith Greener Grid Park will mean that “will become a thing and rotor assembly. Forgemasters has of the past”. GE will apply typical manufacturing processes such as mobilised a lot of turning, milling, vertical boring, pressing, ame cutting, resource to ROTATING MACHINE TECH welding, just in larger scale. The stator is fully made by completing the In delivering the project for National Grid ESO, Statkraft UK GE’s Power Conversion business, including the 35,000 work and GE Power Conversion will provide stability services to pressed steel laminations and all the fabrication work. help keep the electricity system stable, such as inertia Laminations are punched on 400 tonne presses. (stability), short circuit level and frequency. The rotor shaft forgings are made This has traditionally been provided by using the kinetic from some of the largest available energy in the spinning parts of large generators when they ingot sizes, forged using hydraulic were providing electricity onto the grid. The rise of non- presses, manipulated, and then synchronous generators such as solar, wind and turned to the required sizes on large interconnectors mean these services are now more machining centre lathes. The stator important and are being procured separately. is vacuum pressure impregnated The project leverages GE’s experience in rotating (VPI) in Rugby, home to the largest machine technology, as the rotating stabiliser solution VPI vessel in Europe. provides a way of replacing the stability services provided GE Power Conversion industry by traditional thermal plant generation, but without CO2 business director Ed Allison emissions. As a result, fossil fuel powered generation does explains the project came to fruition not need to run, which allows more renewable generation to after his company and Statkraft operate, providing secure electrical power at a lower cost to realised early on the high consumers. penetration of renewable energy The core of the Keith Greener Grid project is two rotating would transform the grid network. stabilisers being manufactured in Rugby by GE Power “Back in the 2010’s a small-scale Conversion, using the rm’s innovative electric machine demonstrator project was built technology. The innovation bene ts from the combination of successfully in Ireland. The Green a long experience in technology from impulse generators Park project is the full-scale used in the Fusion research industry and expertise in hydro- commercial outcome of that long generators. GE says the machines are “around the weight dialogue, relationship, and
Lister Drive Greener Grid Park
Statkraft has also recently announced a second grid stability project service contract. in Liverpool and has named ABB as the rst supplier in the £25m The site at Lister Drive will be one of the rst sites to use this Lister Drive Greener Grid Park, which will be constructed later in technology to stabilise the supply of renewable energy to the grid in 2021 with further supplier contracts announced soon. the UK, joining Australia and Canada. The Lister Drive site will have two synchronous condensers, ABB’s synchronous condensers will provide a neutral emissions engineered and installed on site by ABB’s UK team ( www.is.gd/ alternative to stability services from traditional thermal plant olUDKZ ), based in Warrington. generators. The project will also help to decarbonise the UK’s energy sector by Statkraft UK managing director David Flood, says: “Working with allowing the grid to better adopt renewable energy and provide a low ABB’s team in Warrington we will be able to use proven technology in emissions alternative to regulation through traditional generators. an innovative way to deliver grid stability without carbon emissions.” ABB will engineer and install two synchronous condensers on the ABB managing director David Hughes, adds that the rm’s site. This is a new use for the technology, which has historically been innovative technology, supported by a long-term service contract, will used to maintain voltage on long transmission lines. Working closely make it possible to add additional renewable generation “as the UK with Statkraft, ABB’s UK team will support the site with a ten-year transitions to a more environmentally sustainable future”.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 11 LEAD FEATURE STABILISING THE GRID
part, namely a new BOST RAM horizontal floor borer and BOST five-axis vertical turning lathe (VTL), weighing almost 250 tonnes. These are the only machines of this capacity in the UK and completed a large proportion of the finish machining operations involved. The BOST five-axis VTL has maximum machining height of four metres, maximum swing diameter of 8.5m, table weight capacity of 100 tonnes and embraces modern Industry 4.0 techniques of process control, adaptive control, and real-time interactive maintenance protocols. The forging process is a complex undertaking, as once the hot ingots arrive into the forge are forged on the 10,000T forging press, rough machined and ultrasonically inspected in the south machine shop, quality heat-treated in the forge and then finish machined. There is little leeway for error and the machining tolerances are extremely tight in forging the product. Due to mutual interest in cleaner energy,” he says. tight deadlines to complete this project, Sheffield Allison explains GE is to continue to contribute to energy Forgemasters says it has mobilised a lot of resource that it transition and play a part in the carbon neutral 2050 has dedicated to completing the work and the expected targets and the firm’s contribution extends beyond the UK – time for completion is between 9-11 months. and it is supporting sister business, GE Renewable Energy, Senior sales manager Kunal Popat explains how the with the deployment of one of these machines on the wind company got involved: “SFEL were approached with the farm, Murra Warra II, in Australia. concept by GE Power Conversion in 2018. “Both sides worked together on design and technical KEY COMPONENT aspects over the next couple of years including suitability of Sheffield Forgemasters is manufacturing the main rotator material.” shaft and hub for the project, which are both made of low There are a number of similar projects for various sites alloyed steel with contents of carbon and manganese. globally and Popat says Sheffield Forgemasters hopes to The finished piece will be around 175 tonnes in weight and win some more contracts: “Given our involvement and the rotator shaft was transported to the GE factory at the levels of expertise shown on this project, we anticipate end of February. being involved with future manufacture of similar rotating A combination of machine tools are being utilised for the stabiliser parts.” ■ Renewable electricity usage outpaces fossil fuel for the first time
The UK’s energy mix is experiencing huge growth in renewable This was mainly driven by an increase in wind power. For the first generation and National Grid ESO data shows that 2020 was a time, 24% of the UK’s electricity was generated by wind turbines in record-breaking year for clean energy, as the UK achieved 5,147 2020, up from 20% in 2019. hours of coal-free energy supply and reached new records in wind While wind showed growth, solar and hydro made up only four per and solar power. cent and two per cent of the UK’s electricity production respectively. A recent report by the thinktank Ember found the UK’s renewable Solar remained stagnant, which Ember says reflected “the lack of a electricity outpaced its fossil fuel generation for the first time in supportive policy environment for the technology”. 2020 and could remain the largest source of electricity in the future. Bioenergy generated 12% of the UK’s electricity in 2020, posting Ember says renewable energy generated by wind, sunlight, water slight growth since 2019. However, Ember says bioenergy is a much and wood made up 42% of the electricity last year compared with higher risk source of renewable electricity – for both climate and 41% generated from gas and coal plants combined. Nuclear plants environmental outcomes – than the other sources such as wind and generated the remaining 17%. solar. Further wind and solar growth will enable the UK to stop The thinktank adds with coal power already near zero, fossil gas burning wood for power. was forced to a five-year low in 2020 by growth in wind power and Coal generated two per cent of the UK’s electricity in 2020 and below-average demand due to Covid-19. While UK renewables with rising renewables (+12TWh) and falling electricity demand production is dominated by wind, it still remains overly reliant on (-17TWh) due to Covid-19 drove fossil gas generation to a five-year risky bioenergy, which Ember says must be replaced with cleaner low. However, gas remains the UK’s single largest power source, power to fully decarbonise the UK grid. generating 37% of UK electricity in 2020.
12 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets tradition traditionof excellence of excellence
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DMG Mori’s Open House in Pfronten, Bavaria, Germany, is a major UNIVERSAL MILLING event for the company, but due to the Covid-19 pandemic, it was held Taking centre stage were three machine tool premiers. The rst was the CLX 450 TC and online this year, where the machine tool manufacturer revealed three its compactMASTER turning/milling spindle, new world premiers which has been launched in response to the increasing demands in universal turning. Universal machines from DMG Mori have ike all machine tool industry players, big When asked about how he sees the been an integral part of the machine park of or small, DMG Mori ( www.is.gd/Cul0iC ) future of the machine portfolio, Mori says numerous CNC operations for decades, but Lhas not been immune to the impact of horizontals for 5-axis machines, unique with the new CLX 450 TC, the machine tool the Covid-19 pandemic, but the tone was one devices for automation and service from its manufacturer has looked to rede ne of positivity for the year ahead at the annual engineers will be vital moving forward. universal turning. February Open House. Thönes adds on this: “We will continue In order to meet increasing production Speaking at the opening, president with innovations, but we already have this requirements with smaller quantities and Masahiko Mori (picture above right) says great portfolio. It is very important that our greater part diversity, the new series with DMG Mori weathered the storm in 2020 customers nd a solution in a one-stop- the CLX TC has been established, in which a and he believes in 2021, especially after shop from the beginning up to the big B-axis with compactMASTER turn and mill the summer period, it will be “very busy” for machines. Technology integration is also spindle replaces the traditional tool turret. the machine tool industry and its customers very important.” On board are an automatic tool changer and he is upbeat about the next 12 He explains the “total architecture” for with tool magazine, the usual powerful main months. machine tool manufacturers is vital moving spindle and the tailstock or an optional Chairman of the executive board forward and DMG Mori will develop its counter spindle, which DMG Mori’s says is Christian Thönes (pictured above left) also portfolio to give customers a complete end- the “perfect entry into 6-sided complete notes that in 2020, the company speeded to-end solution, including digital machining”. up innovation, used the time and kept engineering, machine, automation and The central element of the new CLX 450 development programmes and people digitisation, along with the integration of TC is the B-axis with the compactMASTER stable. “I am very con dent with this more technology, enabling customers to be turn and mill spindle. A Y-axis allows enlarged portfolio, and good innovations we “stronger and more competitive”. eccentric machining even in the standard can come out of a dif cult year in 2020 and “I am fully convinced in the next one, version, while the tool magazine with up to have a very good year in 2021,” he adds. two or three years, there is a window of 60 places – the standard is 30 – enables Automation, digitalisation and opportunity where people have to think the production of several different sustainability will continue to be core about the right investment decision, and components without intermediate tool focuses in DMG Mori’s strategy and both not only about the machine, but the total setups. Tools can be loaded and unloaded in Mori and Thönes say the company will architecture,” adds Thönes. He says DMG parallel with machining time, so set-up times continue to innovate. It now has a portfolio Mori is well positioned due to its DNA and are once again signi cantly reduced. of 154 machines and offers 53 automation innovations to work in close partnership The B axis also bene ts process stability solutions. with customers on this total architecture. and the risk of collision is also signi cantly
14 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets SUPPLY SIDE DMG MORI DIGITAL OPEN HOUSE
The CLX 450 TC has been launched in response to the increasing demands in universal turning
Thanks to the design based on The M1 offers an easy-to-operate and monolithic machine bed and xed table user-friendly control Siemens 828D, while the M1 the company explains achieves NC programs can be easily and quickly “exceptional performance” in its class, transferred, since Siemens 828D and 840D while high static and dynamic rigidity, as are fully compatible. The M1 is equipped well as perfect damping properties result with IoTconnector which secures the in stable machining process. connectivity at the customer shop oors, as The new M1 assures high surface well as an access to the digital future. The quality and increased tool life, all that IoTconnector enables the users to bene t lower with a tool in the workspace. A turning combined with a highly attractive price. The from various DMG Mori software and digital length of 1,100 mm and 400 mm turning huge thermal capacity of all components solutions like NETservice, Service camera diameter provide suf cient space for a wide makes the M1 less susceptible to thermal or my DMG MORI customer portal. variety of components. deformation. What is more, the DMG Mori meets different equipment On the control side, the CLX 450 TC is inlineSpindle, developed and built by DMG requirements with the three coordinated equipped with a Siemens 840D solutionline Mori, has already been installed on more variants M1 complete, M1 plus and M1 and a 19” multi-touch panel. The exclusive than 3,000 machine tools worldwide. pro. DMG Mori technology cycles for CNC machining speed up handling, process The M1 is DMG Mori’s fi rst monitoring and programming by up to 60 move into the entry-level per cent. market segment
NEW MARKET ENTRY Interestingly, the second world premier is a move for the rst time into the entry- level market segment with the new M1 that DMG Mori says offers “outstanding milling performance and high rigidity at a competitive price” and a new “master- class for every shop- oor”. With 45 product lines, DMG Mori offers its customers a variety of machine tools for every metalworking application. This time, the engineers from Famot in Poland discovered an attractive market potential in the entry-level area of simple, 3-axis milling centers. The company explains the biggest challenge for most companies is to The DMF 300|8 follows on constantly reduce the production costs from the launch of the DMF to stay competitive in the market, so it 200|8 has met customer needs and requirements with the new M1 machine tool. From very small companies or start- ups which need a cost-effective solution, as well as big production plants which are looking for simple and accurate 3-axis milling machine, DMG Mori says the combination of quality with an unbeatable price makes the M1 a “perfect solution” for all 3-axis parts, which do not require machining process on more expensive and more technologically advanced milling centres.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 15 SUPPLY SIDE DMG MORI DIGITAL OPEN HOUSE
SETTING NEW STANDARDS to the previous model. The machining large The third premier was the DMF 300|8 with innovative tool change of shafts, among other up to 3,000 mm in length or shorter parts in the new machine concept things. two separate workspaces, following on from also contributes to this. The constantly cantilevered the DMF 200|8. In addition, the machine Y-axis ensures consistent machine The larger DMF 300|8 has a 3,300 mm can be equipped with 400 mm rigidity over the entire traverse path. This long table offers users maximum exibility long tools – a unique selling point in this means the maximum spindle power can be even when machining long workpieces. A machine class. called up regardless of any spindle position new highlight is milling-turning machining, The option portfolio of the DMF 300|8 in the working area, without the machine which optionally extends the machine’s also offers users maximum exibility. The swinging open. Extensive cooling measures universality and creates new solutions machine can be optionally equipped with an as standard ensure high long-term thermal for customers. integrated rotary table, with two accuracy with the lowest tolerances, while The DMF 300|8 bene ts integrated rotary tables, or with an directly driven ball screws in the Y and Z from the same innovative add-on table as an A axis. This axes ensure the best surface nishes. machine concept as the means there is hardly any limit In its basic con guration, the DMF 300|8 DMF 200|8 – a constant to the exibility in terms of travels at rapid traverse rates of up to 50 cantilever ensures work tables. The optional m/min. With the optional linear drive in the consistent milling partition wall creates two X-axis, it reaches up to 80 m/min, ensuring performance over the entire separate work areas that can be dynamic and highly productive machining at working area, the newly set up independently of each all times. The extensive modular system developed tool change takes other in parallel with production. also includes a wide variety of place behind the worktable Chairman of the executive DMG Mori is also presenting speedMASTER spindles with the already in a process-safe manner, board Christian Thönes another novelty in the DMF familiar 36-month warranty, regardless of and a holistic cooling series: the modular construction mileage. concept ensures very high long-term thermal kit is supplemented by an FD rotary table for On the control side, the DMF 300|8 is accuracy. demanding and ef cient milling-turning equipped with Celos and Siemens as The working area of the DMF 300|8 was operations. This is also available for the standard, but Heidenhain is also available increased by another 60 per cent compared DMF 200|8 – just like the optional A-axis - for as an option. ■
DMG Mori reports 2020 fi gures
DMG Mori reports that 2020 was still a strong year despite dif cult our global footprint, broad machine portfolio and far-reaching service market, geopolitical uncertainties, industrial restructuring and offerings DMG Mori is well positioned.” economic conditions globally due to the Covid-19 pandemic. DMG Mori notes domestic orders in 2020 were €462m (2019: The company says in 2020 global demand for machine tools €714.8m). International orders amounted to €1,137.4m (2019: was “declined signi cantly” and it could not entirely escape these €1,848.3m). The share of international orders was 71 per cent factors so order intake, sales revenues and result were below the (2019: 72 per cent). record year in 2019. The company says its focuses on green machine production However, the rm explains the negative effects of the crisis and technology leadership and environmental protection are “in were limited by “rapidly introduced and consistently implemented harmony” and sustainability has been an integral part of the measures” to reduce costs, increase exibility and secure liquidity – corporate strategy for many years. Since May 2020, DMG Mori while maintaining a stable budget for research and development. notes it has an equalised CO2 balance. The company’s preliminary gures for the nancial year show the In addition, DMG Mori explains it has achieved an ambitious order intake was down 38 per cent on 2019 to €1,599.4m (2019: sustainability target, as all machines delivered since January 2021 €2,563.1m), sales revenues at €1,831.3m - below the record year are produced worldwide – from raw material to delivery – completely of 2019 (€2,701.5m) and earnings before interest and taxes (EBIT) climate-neutral, meaning it is one of the rst industrial companies to amounted to €81.7m (2019: €221.7m). have a climate-neutral product carbon footprint. Chairman of the executive board Christian Thönes, explains: As for 2021, DMG Mori states it is “strategically and nancially “DMG Mori has ful lled its forecasts, is holding course and goes well positioned” and the global machine tool consumption is strengthened into the future. expected to recover slowly in 2021 after the sharp decline in 2020. “The pandemic has accelerated a lot. Above all, automation, The Japanese-German machine tool giant’s main focuses areas are digitisation and sustainability. With this strategic triad as well as automation, digitisation and sustainability.
16 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets SUPER SPEED HAAS SUPER SPEED MACHINES FOR HIGH VOLUME MANUFACTURING
SUPER MINI MILLS DRILL/MILL/TAP SUPER SPEED VMCs 5-AXIS UMCs ROTARIES UP TO 15,000 RPM UP TO 20,000 RPM UP TO 15,000 RPM UP TO 15,000 RPM UP TO 830º/SEC
HAAS AUTOMATION • 01603 760539 • [email protected] • HAAS.CO.UK MACH The Tempest will join the RAF in 2035 as a 2022 replacement for the Typhoon Eurofi ghter “Collaboration is at the heart of what we are doing to prove,” says Holmes. “In terms of experiments in the manufacturing arena, preview week we want to look in adjacent areas in emergent technology areas and extract the companies Last year’s biennial MACH show was cancelled due to Covid-19 and learning and experience giving us a game- changing solution.” has been rearranged for April 2022. The MTA, organiser of the event, As part of the development, BAE Systems held a digital preview week featuring various seminars highlighting is developing a ‘Factory of the Future’ that is innovative new projects and technological developments digitally connected and takes on emerging technology and fuses them together. Digitisation is a major part, and the rst ACH 2020 had to be cancelled due technology his company is using in the step on the journey has been harnessing to the Covid-19 pandemic and will development of its Tempest UAV programme. digital data to maximise operational Mnow take place in April 2022 and as The Tempest is the next-generation combat effectiveness, explains Holmes, including an part of the preparations, the exhibition’s aircraft, operating at the cutting-edge of Industrial Internet of Things (IIoT) platform, organiser the Manufacturing Technologies technological innovation aimed at securing the real-time visualisation, ensuring operational Association (MTA) ( www.is.gd/Edf4l3 ), UK’s position as a global leader in air defence ef ciency and exploring the use of arti cial organised an online preview week at the end and combat. The program is set to deliver intelligence (AI). of January featuring high level seminars. world rsts in advanced technical capabilities. Holmes says the project will also exploit MACH 2022 will take place from 4-8 April The new aircraft will eventually join the RAF advanced manufacturing technologies to at the National Exhibition Centre (NEC) in in 2035 as a replacement for its Typhoon create new value in optimising the design, net Birmingham and feature a range of zones Euro ghter. By end of 2020 more than 1,800 and near-net components and digital toolset showcasing manufacturing technology. It is people were working on Tempest across development. set to attract 25,000 visitors and more than government and industry, increasing to more “We wanted to explore a number of novel 600 exhibitors, connecting UK manufacturing than 2,500 in 2021 with over 600 suppliers technologies – so much has been made of engineers, decision makers, buyers and engaged on the project. disruptive technology and materials going speci ers with suppliers of new technology, Holmes explains to maximise the project’s forward,” says Holmes. “The system allows equipment, services and processes. technology development capability its us to rapidly create ideas to apply loads where framework brings together digital manufacture, needed and create parts quickly and MAXIMISING TECHNOLOGY DEVELOPMENT automation and autonomy, competitive tooling effectively – reducing time to market, being Among the seminars was a fascinating talk by and xturing, additive manufacture, high more energy ef cient and producing higher David Holmes, director of operations and integrity metallic processing, advanced integrity parts, which brought some signi cant technology for air at BAE Systems, who materials and smart structuring and effective changes and challenges. offered an insight into the manufacturing product test and veri cation. “In terms of where we are exploring the
18 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets EXHIBITION PREVIEW MACH 2022 DIGITAL PREVIEW WEEK
additive space, we are moving away from automation throughout all of our Oliver Selby, robotics development desktop trinkets into very large near-net shape manufacturing, including SMEs.” business manager at Fanuc ( www.is.gd/ components that brings together challenges Ashley Page, director of sales at Hydrafeed e0EzQG ), feels it is imperative for SMEs to get and opportunities around the UK, looking at ( www.is.gd/Fz3MOm ), a rm supplying CNC a specialist automation expert to come in and machine tools and af liated processes so we barfeeding equipment, robot automation look at certain processes. can build and produce parts for this integrity equipment for all types of CNC turning and For example, there might be a high degree and size. milling machinery and bespoke systems, of staff deployment within one application or “That is a game-changer for the aerospace identi ed reasons why automation is needed process, but the independent automation and defence sector, but is only being enabled by SMEs. specialist might identify something different. by these modern digital toolsets and the He says: “There are number of challenges Katherine Nowill, marketing manager for effective supply chain that sits around that.” including market changes, a high mix of low to UK & Ireland at Kuka Robotics ( www.is.gd/ A key part of the project is developing medium batch runs, demand for more aMby8G ), recommends SMEs rst need to multifunctional, autonomous capabilities with complex components and machine tools understand what they are trying to achieve autonomous drilling, mitigating restricted themselves requiring high skilled engineers before making investments in automation. access and developing cobotics. Integrating with quick reactions, reduced lead times, less She notes it can be bene cial for company everything together has been vital and BAE stock held and enhanced quality control. leaders to conduct a “walk-the- oor” exercise Systems is using a Siemens toolset and “All of these challenges build to the to establish what areas can bene t most from smart electric tools. automation must be three key things – which automation and provide the best returns. Holmes says it has created an agile, our products offer, and they must have Nowill notes though that automation recon gurable assembly capability with robot- assisted assembly and initial development, The Simple Steps to Automation for SMEs panel featured a wealth while developing a build philosophy, of industry experience understanding positional accuracy, product agnostic and robot enabled stack drilling. Every process being worked on and developed will eventually lead to a design phase in around 2025, leading through to the 2025-2030 pre-production build cycle and ights in the early 2030s.
DRIVING AUTOMATION Also featuring in the preview week, was a panel session ‘Simple Steps to Automation for SMEs’ chaired by Mike Wilson, chief automation of cer at the Manufacturing Technology Centre (MTC) ( www.is.gd/b7vOKH ). He leads the centre’s drive to increase the adoption of automation throughout UK manufacturing and the session also featured exibility, quick changeover times and be easy should not be applied on shop- oors just “for experts from across the automation sector. to use.” the sake of it” but says by automating SMEs The UK is behind the rest of the world in Key bene ts of investing he says are a show they are forward-thinking and at the terms of automation usage and Wilson notes decrease in labour costs, expanded forefront of technology, which can boost that according to the International Federation productivity periods, multi-control of machines business. of Robots (IFR), which measures robot through a single operator, quick responses to Cobots also have a role to play and provide deployment, the UK is 24th in the world in uctuations in demand, increase in spindle bene ts for SMEs, notably for simple, terms of robot density. hours, gross margin and revenue growth and repetitive operations in a factory, according to “We are the 9th largest manufacturing overall return on investment (ROI). McCullough. nation in the world and I would expect us to Peter McCullough, product manager for He notes they give the ability to put in be somewhere more around the 9th or 10th Doosan Robotics within Mills CNC’s ( www. place on a production line, a exible easy-to- position, so we are lagging behind some of is.gd/OIjyom ) automation division, feels for implement automation solution, as can work our major competitors and there are various SMEs to successfully apply automation, they with an operator in a collaborative reasons for that,” he says. must nd a product that gives the best ROI, is environment, risk assess and can do “The key thing if we are going to remain easy to use and they must look at a process applications – taking away repetitive competitive going forward is, we need to see and decide how automation can improve it, operations and allowing human operators to more widespread use of robotics and while keeping it simple. do the more “value-added” tasks.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 19 EXHIBITION PREVIEW MACH 2022 DIGITAL PREVIEW WEEK
decarbonising is going to be at the forefront of any priority. “We have two opportunities – one is to think of think of our technology and the products we are creating and selling and whether they have a decarbonising impact. “We must look at our manufacturing operations and maybe adjusting to be in more emerging sectors that are being created.” The second is research and innovation that links to the green agenda, which Maier notes Made Smarter will be a key and acting part of the ecosystem through its ‘Innovation Programme’ – in creating and developing technology. PROJECT ELLI partners and UK This programme is funded The MACH 2022 digital preview week also manufacturing along with via £147m of government shared the spotlight on an innovative and the Caterham sports car. funding that will be match interesting project taking place at the The lightweighting funded by industry and create University of Shef eld’s Advanced demonstrations focus on the more advanced digital Manufacturing Research Centre (AMRC) work of their additive technologies for UK manufacturing. ( www.is.gd/PzYmL6 ). manufacturing, advanced Made Smarter is running innovation Jurgen Maier, chair of the Project ELLI (Electri cation and composites and machining Digital Catapult and co- competitions and hubs to drive Lightweighting in Industry 4.0) is centred on a teams. Reducing the mass of chair of Made Smarter development of manufacturing development Caterham sports car, which driveline components is crucial technologies. exhibits the AMRC’s capabilities in mid-TRL for improved ef ciency, by re- The third lever Maier says is the research across multiple sectors. modelling the propshaft with innovative adoption of technology and he urges ELLI encompasses the skills of ve windings and titanium printed universal joints, companies to be on the journey, as it is vital different AMRC capabilities including, the savings are 60 per cent. to adopt more advanced digital technology to lightweighting, battery cell manufacture, Electri cation is being driven by the EPSRC improve operations and competitiveness. 80% automation, additive manufacturing and Future Electric Machines Manufacturing of UK manufacturing are on the way to advanced machining, each of which has (FEMM) Hub and the AMRC North West’s adopting technology and be Industry 4.0 developed a manufacturing demonstrator for automotive electri cation and battery enabled by 2025, according to a Make UK an automotive assembly operation. assembly strategy. Within this, the AMRC are survey. Selected complex assemblies are being performing research and development to Lastly, is taking leadership and the cultural utilised by the AMRC to create a series of safely assemble high voltage battery systems development of workforce digital skills. Maier nal products in order to provide a supply in a more controlled and cost-effective manner urges business leaders to take leadership in chain of advanced components. and the automated assembly of electric getting members of their supply chain to “get Rab Scott and James Lindsay, from the motors. on the journey to digital adoption” and in AMRC, explain the aim is to ultimately ensuring staff are upskilled and trained on increase productivity for the project’s partners DIGITAL LEVERS how to use digital tools. and UK manufacturing in general. Another seminar featured Jurgen Maier, chair MTA chief executive James Selka, says it Scott says the focus areas are to improve of the Digital Catapult and co-chair of Made made sense to utilise the strong digital the productivity by improving quality, removing Smarter – a programme leading the UK’s platform in support of MACH. He adds: “One rework, expose the digital thread through the plans to grow manufacturing through digital of the MTA’s aim was to provide the UK’s process and value chain, and sustainability, technologies, innovation and skills. manufacturing community with the latest including environmental towards net-zero, The focus of his presentation was low- insight into productivity improvements. The economic in shared prosperity and social – carbon industry and four key levers or MTA is constantly communicating with the top providing opportunities for all. opportunities that UK industry “can pull” to tiers of the UK manufacturing community and Project ELLI will be centrepiece of the make the best of the UK’s green this will prove bene cial as we continue to AMRC’s stand at the MACH exhibition, manufacturing recovery or revolution. build towards MACH 2022. demonstrating how they are leading mid-TRL The rst is decarbonisation and the green “The great content we were able to secure research across multiple sectors and economy, says Maier: “I think the push for was testament to the ability of the speakers capabilities, increasing productivity for AMRC everything we do being greener, and to engage and inspire their audience.” ■
20 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets Fast and precise component workholding? The answer’s YES
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At the heart of the metal forming industry The MMMA is growing its membership despite a diffi cult period due to the Covid-19 pandemic and will showcase everything it offers in its largest ever Metalworking Village at MACH 2022 next April
he Metalforming Machinery Makers ancillary equipment manufacturers and challenging, as key trade show MACH 2020, Association (MMMA) ( www.is.gd/ British-based importers, adding to previously which is a critical event, was postponed due TZ6SVmC ) has been representing the evolving to also include roll forming and sheet to the Covid-19 pandemic, but the MMMA has UK’s power press makers since 1949 and is metal machine manufacturing companies. used the time to help members and plan for the only UK association solely dedicated to The MMMA can now count on 41 MACH 2022 in April next year, where it will the sheet metal forming industry. members, with more than 20 added since the host its biggest-ever Metalworking Village. The association’s membership has been rebrand that now even features recruitment growing strongly after it changed the rm Glen Callum Associates, training KEY TO THE RECOVERY membership criteria three years ago to company In-Comm Training and Business Since the outbreak of Covid-19, the sheet include Services and a safety expert. metal forming industry has like many The last 12 months have been industries suffered, especially as it is heavily reliant on the automotive sector. However, Bruderer BSTA 410-110 the MMMA is positive about the prospects for stamping press the industry and its members in 2021 and believes there will be a strong recovery. Chairman Adrian Haller, managing director (MD) of Bruderer UK ( www.is.gd/WmgYvX ), a key supplier of high speed presses of 10-to- 1000-ton capacity in the UK, says it has been a challenging period on different levels but business has proven to be resilient. “It’s been dif cult, no question, and a double whammy with both Covid-19 and Brexit challenges, but on the whole very promising. Our industry is used to ever-changing environments with one thing and another. “Another dif culty has been trying to get engineers into our customers and most of our industry has ageing workforce so have had to shield, which has proven to be another big challenge, as during the rst lockdown, no hotels or amenities were open so working on
The Metalworking Village at MACH 2018
22 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets site was very dif cult.” Right: MMMA chairman Haller believes that manufacturing and Adrian Haller engineering hold the key to the UK recovery and is the only way to get the country “back Below: MMMA up and running” at full capacity, forecasting a vice-chair Phil Leath-Dawson V-shaped recovery. He is very positive about the year ahead and for the future of the sheet metal forming industry. Vice chairman Phil Leath-Dawson, MD of Schuler UK ( www.is.gd/3B0JjO ), a provider of mechanical and hydraulic presses, feels the biggest challenge now is the continued uncertainty. He explains that due to being a heavily automotive-based industry, many power press makers have faced strong headwinds, although there is a drive to diversify away from being too reliant on the sector. “It has been really dif cult as we have been fully-booked for periods, but then there have been these huge voids of nothing in between,” says Leath-Dawson. “That is the these innovations come forward it biggest problem we face, as before we could will naturally diversify as these plan things, but there is no consistent opportunities are created.” MMMA members grow their business. business and we do not know what it will be Reshoring UK will also prove an invaluable from week to week. BREXIT AND RESHORING tool for the MMMA to grow its membership. “The majority of our members have said at The UK left the European Union (EU) at the Marketing coordinator Bill Neal explains: our meetings that they are ticking over and end of 2020 when the transition period “It is up to us to keep our members up-to- surviving. Much of this is down to the ended, but will this move have an impact on date about what opportunities are out there government furlough scheme supporting them the sheet metal forming industry? for them, as certainly, the indications are – but it is challenging.” Leath-Dawson is sure that leaving the bloc there in some industries that companies are He forecasts that due to the UK’s will provide a positive boost to the industry. looking to bring production back into the UK. dependence on the automotive sector, the “We go back to the 1970s slogan ‘Buy “When they do that, these companies will economy will recover to pre-pandemic levels British’ and things start to be more nationally need to employ the latest production in two years, rather than by the end of the produced which will be good for techniques and technology in order to year as predicted by some. manufacturing and our economy. I think it will compete, and many of our members are in The sheet metal forming industry has have a stronger local focus that will be great the right position to deliver that.” traditionally been quite dependent on the for our industry.” automotive sector, but is looking to diversify Haller concurs, and feels the reduced BLACK HOLE into other sectors and there are major bureaucracy will help boost trade to other The engineering industry is suffering from a opportunities on the horizon, notably in the markets so leaving the EU allows the UK to skills shortage and a lack of talent coming electric vehicles (EV) and medical sectors. spread its wings, opening up new through, as the younger generation would Leath-Dawson believes things will naturally opportunities across the globe. often rather pursue other ways of forging a diversify to sectors, such as e-mobility and EV Due to the Covid-19 pandemic a career and making money – leaving which is an ever-growing market, as every Reshoring UK ( www.is.gd/wA7tpx ) programme somewhat of a ‘black hole’ knowledge gap. electric motor has to have several metal was launched to bring back more One of the aims of the MMMA is to boost stampings, while are also other applications manufacturing and engineering home along interest in engineering and careers in the that many would not think metal forming with some concerns over the UK’s reliance metal forming industry, making it more plays a key role. on global supply chains. This initiative is desirable for young people to follow a career “The UK is leading EV technology globally being rmly backed by the association. path in it, as there is a lack of skilled at the moment and there is a lot of innovation Haller feels the programme is “absolutely engineers in the 20s to 30s age range. going on and taking place with several new essential” and is much needed by the UK’s Leath-Dawson believes the skills shortage start-ups for passenger and commercial power press makers, providing an opportunity is “massive issue” for the industry and the vehicles. There is a great opportunity and as to pull together to grow business and help biggest challenge it faces, as the average
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 23 METAL FORMING GROWING PRESENCE
Machine Tools Ltd, Ross UK, Aida SRL UK and OSA Systems. Among new technologies and services on display in the MACH 2022 village will be a new range of Boxin mechanical power presses from Raybould Machine Tools; the BSTA 280-75B high speed Stamping press and BSV75 servo feeder from Bruderer; a new range of die cars 500-1600kg and magnetic clamping from Roemheld The Bruderer stand UK; and the Titan Press from at MACH 2018 “We are striving to Worcester Presses. be more exposed and Neal says 26 of its age of employees is so high, but they will some sign of electronics or as such, contactable for members were signed up for need to be replaced sometime in the near computer-control with it anything to do with MACH 2020 and it already has future. and if you do not 22 on-board for MACH 2022, “For the last 20 years engineering has understand them both then machine tools and despite the challenging been looked on as a bit of a ‘dirty industry’ you have not got it,” he manufacturing” business climate. “At the current and is not appealing enough for young says. position that is extremely positive, people, as they can make more money on However, despite the and we are looking at having over YouTube and think - why would I want to do technological advancements in 650 square metres within the village. We engineering that takes four years to serve an machines, Haller believes engineers still need are talking to the MTA to get the village more apprenticeship in before I can start adding to understand traditional skills and how to established in its own right.” value,” he says. use traditional milling machines like reverse The MMMA kicked-off its MACH “The bene ts of bringing in this mill, end-mil, before they can go on to a CNC programme in February and is trying to get recruitment company in, are we can make machine and need to know the basic skills, members to commit to a speci c stand size, engineering more appealing to people. There but also have electronic skills in the back of which is tough due to marketing budgets are great individual skill sets out there, but it the mind. being constrained due to the pandemic. is making them understand that engineering He adds: “We have got to train time-served However, on a positive note, the MMMA is somewhere these skill sets can be used.” engineers from senior guys through to the has a wider pool of members to attend than Haller notes there a wide range of youth who have the electronic skills. You still previous MACH shows, as for MACH 2018 engineering opportunities for the youth, but need the seniors to look at this and do that, and the cancelled 2020, it could only boast the industry has to market itself better and but that is where our black hole is at the around 17. more attractively to attract young people to moment. Neal says: “We are growing and have pursue careers. “We are training these guys up by the been building over the last few years and are At MACH 2022 as in previous events, senior guys, who are ready to retire and there now bringing a number of bene ts to the students will be taken around the event and is a black hole, where we have lost years and table. One of the things we have been driving the MMMA Metalworking Village, which years of experience.” to our members, is it is their association so presents a chance to show what use it, such as our social media platforms. opportunities are available and how BIGGEST EVER VILLAGE We have more of an opportunity to deliver a interesting a career in metal forming can be. The MMMA has ambitious plans for its bigger and better village at MACH 2022.” Haller says: “The more we can get young Metalworking Village at MACH 2022, where Haller concludes: “We are striving to be people coming to see things for themselves – members will showcase their skills, services more exposed and as such, contactable for the better. You need to get into their and technologies to visitors from across UK anything to do with machine tools and knowledge and see whether they want to manufacturing. manufacturing, inciting conversation and work on these machines, do they want to Members already signed up to exhibit at thought. work for a living and are they prepared to put the show include Bruderer UK, Esprit “Our membership has stayed extremely ve years of time and understand how it all Automation, Cotswold Machinery Sales, strongly with us over the last 12 months as works.” Worcester Presses, Schuler, Presscare, TMA, they are seeing the bene ts of all the Digitisation is evolving fast in the metal Roemheld UK, Industrial Clutch, Kaller Gas changes that we have made. forming industry, like in many industries and Springs, Press Techniques, Helm “The MACH will be excellent for us to Haller believes that the key job skill for any Instruments, Anton Saws, Qualimach, Wilson showcase everything that we offer as an young engineer coming through is Tools, Pressform Machinery, Ortlinghaus, organisation.” mechatronics. “Every machine tool and Decade Monitoring, Group Rhodes, Oerlikon Visit www.mmma.org.uk for more everything you touch nowadays, there is Balzers, Voith Turbo UK, Formit, Raybould information about the MMMA. ■
24 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets HEAVY ENGINEERING DEVON DELIGHT Making the difference General manager Heavy engineering is a competitive sector, Joe Wilcox but Devon-based Blackhill Engineering has won a major contract and is looking to grow business even further in 2021
evon-based Blackhill Engineering has As part of the work, it fabricated 15 square foot workshop capacity divided been boosted by winning a major sacri cial casings measuring up to 18m long between fabrication, assembly and a large Dheavy steel fabrication contract for with a diameter up to 2.3m and weighing up and small machine shop. VolkerStevin on the Thanckes Oil Fuel Depot to 23 tonnes each, which will be embedded The rm’s 50 tonne lifting capability is a Loading Facility Refuelling Jetty in Cornwall. into the rock strata of the River Tamar to unique resource in southern England and it The Exeter located heavy engineering form stanchions supporting the jetty head has built up a portfolio of customers across specialist has fabricated structures for the structure. It is also fabricating dolphin tops, multiple sectors including marine, temporary and permanent works utilising its rails, frames and access equipment. automotive, defence, oil & gas, renewables Goratu GBM CM4 Universal 4m Bed Mill, The contract expanded with Blackhill and nuclear. along with other XYZ ancillary milling building 6m wide platform structures. The Wilcox explains aside from the machines. feasibility of assembling the completed VolverStevin contract, Blackhill is also part It is the rst contract that Blackhill platforms on its Exeter site and the logistics way through delivering a signi cant contract Engineering has carried out for VolkerStevin, of transporting the nished units to the into HPC, which will run through 2021 and and is part of a £43m Defence Infrastructure customer are being assessed as they would recently delivered several platforms and Organisation project to modernise refuelling require an escorted convoy of vehicles. staircases into the Gosport Oil Depot facilities for Royal Navy warships and Royal General manager Joe Wilcox, who took on Upgrade for J. Murphy & Sons. Fleet Auxiliary. It won the business on the the role just over 12 months ago, says being He explains he is optimistic that Blackhill back of successfully delivering another engaged by VolkerStevin on this major project will have a strong 2021 and so will the UK contract for VolkerStevin, a major engineering is an “achievement” for the rm’s highly heavy engineering sector in general. solutions player in the UK. skilled and exible workforce. “What we are seeing over the last few Blackhill Engineering has a double He adds: “This extension of our working months is there are a lot of opportunities out overhead gantry crane lifting capability of 40 relationship with VolkerStevin has provided there, which are quite reactionary, so it is tonnes and 20 tonnes; this tandem lift further opportunity for Blackhill to show our almost though people have been sitting on capability allows safe loading of structures up capability to add value to our customers and jobs and not quite sure what to do, but the to 25 metres long, something quite unique meet their high priority deadlines even whilst main programme deadlines have not really for the south west. operating in challenging times for the UK. shifted so there is an almost compression of “We’ve been able to demonstrate our work that needs to be done,” says Wilcox. ethos of collaborative working as the design “The main programmes we have at the and the client’s requirements have evolved moment and we are in a good place to do through the project. In addition, this that but we have some capacity throughout contract has provided a relatively steady the year we still need to ll. The order book is workload through Blackhill and our supply looking good long term, but every job does chain through the last quarter of 2020 and come to an end and we are very much a into 2021.” project-focused business at the moment. Blackhill Engineering is part of Devon- “One of my goals is to put in more headquartered SC Group and a specialist steadier, repeat business that we can then heavy engineering business capable of sit the projects up on and is one area we handling large fabrication and machining would like to improve on – and be less projects. It employs 22 people at its two- project, but more product-focused acre site near Exeter with a 28,000 manufacturing contracts.” ■
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 25 Petford Tools uses four Hexagon packages to overcome challenges; Radan software helps Trio Metall diversify its business; Multax Engineered Precision Ltd is boosted by investment in CAM software from Open Mind; plus news and product briefs
Reaping the rewards of software adoption
oolmaking rms that want to be a simulate the toolpaths. Many of the 114 model, the le is imported into WORKXPLORE success and competitive in today’s employees across the group, now use at least for an initial design and feasibility review, Tmarketplace, must utilise the latest one of Hexagon’s solutions. enabling them to provide an accurate costing digital tools and software to stay at the front The rm’s previous system was fully of the job for a customer quote. of the game. Petford Tools has helped integrated into their factory processes and Design director Ian Foy explains overcome ongoing demand to reduce lead although it was a major upheaval to replace it, WORXPLORE was particularly effective at times and costs from initial design concept to managing director Adrian Lloyd says having a reading different CAD formats quickly, so it nal components by turning to Hexagon ( www. fully connected work ow now, with four of can import large CAD les and assess them is.gd/vPRYiQ ) and its smart manufacturing Hexagon’s seamlessly connected solutions, immediately. “This is a major bene t for us, solutions. was “well worth it”. as our previous CAD package was quite The Dudley-based company is one half of Products that are manufactured include lethargic with larger size les,” he adds. the Petford Group, designing and producing interior and exterior automotive trim; interior Any additional index modi cations are done moulds for Petford Moulding, who use them aerospace trim, along with aero engine parts; in VISI. But VISI really comes into its own on their own injection moulding machines to and a wide variety of products for once the order has been placed. “We use it to produce millions of piece parts every year for construction, industrial, rail and marine work closely with the customer on creating a a range of industries. industry sectors, along with commercial nal, feasible cost-effective product for robust Petford Tools is now using four Hexagon trucks, garden-ware, and F1 racing teams. tooling. Then we proceed with full tool design packages: WORKXPLORE, used by the sales Before a project reaches the tooling team, in VISI,” says Foy. team; VISI for the mould designers; WORKNC it has already seamlessly passed through Once the mould tools have been signed for programming their 11 5-axis and 3+2-axis WORKXPLORE and VISI. When the sales team off, the les are imported into WORKNC where machine tools; and NCSIMUL to accurately receive an enquiry, often in the form of a CAD the toolpaths are created for the company’s
26 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets CADCAM & PRODUCTION IT BOOSTING BOTTOM LINES
3+2 and 5-axis machining strategies. This services Petford provides, including tooling The German rm offers complete service software solution provides automated, modi cations, tooling texture, and 24/7 from consulting, designing and planning, to ef cient toolpaths which deliver dramatic breakdown/repairs, along with full CAD manufacturing ‘ready-for-assembly’ productivity gains through shorter machining technical support and project management. components, ranging from single parts and times, longer tool life, the improved surface Lloyd says the connected work ow that small runs, right through to large quantities. nish which Petford Tools need for many of Hexagon brings to their operation, readily Using the latest laser technology programmed their moulds, and better machine utilisation. overcomes their biggest challenge, which is by Radan CADCAM they also work with non- But before starting to cut metal, they need meeting customers’ demands for lower costs. ferrous metals such as copper, brass and to know that the toolpaths are 100 per cent “WORKNC and VISI handle the full data of titanium. accurate. Tooling operations director Dave large models much better than our previous Developed around Radan, Trio Metall’s Parr says: “With 5-axis machining, collisions system, meaning we can import and work on web shop portal gives customers access 24- would be very expensive, both in terms of it quicker,” he says. “This allows us to be hours a day to request components, be money and wasted time, so we run a full more pro cient throughout the workshop. We provided with an offer and place the order. simulation of the G-code in NCSIMUL.” can react quicker with WORKXPLORE at the After going live in September 2019, around This is achieved by virtually building up a start of a project; and NCSIMUL ensures that 500 orders were placed through the ‘Trionline digital twin of the real-life machining there are no holdups during the machining 24’ web shop in its rst year. environment, which also shows tool wear and process.” The system was implemented by Radan’s tool load. German reseller, 3D Concepts, and delivers When the tools are ready, they move to DIGITAL STRATEGY orders digitally to Trio Metall’s ERP system, Petford Moulding to start running off products Meanwhile, Hexagon’s Radan CADCAM which transfers them to Radan’s on 11 Krauss-Maffei and Engle injection software has helped sheet metal component Ordermanager MRP module for production moulding machines ranging from 160-tons to contractor Trio Metall which has based its processing. Completed orders are passed 1,700-tons lock, equipped with pick and place online web shop around the software, back from MRP to ERP, triggering the robotics. enabling the company to tap other markets subsequent processes for shipping and Integrating Hexagon’s four solutions has after traditional orders in automotive and invoicing. This means horizontal logistics are created a single, connected work ow, mechanical engineering declined due to the now digitally mapped, as well as the vertical enhancing the dedicated one-stop-shop Covid-19 pandemic. manufacturing operations.
News and products in brief
■ Doosan Machine Tools ( www.is.gd/ ■ ModuleWorks has released OIjyom ) has integrated the ModuleWorks its 2020.12 CADCAM software cutting simulation technology into its components – the third major Sketch Turn product. The ModuleWorks release that it made last year, software replaces Doosan’s previous which is available for download cutting simulation engine and is part from the company’s website. of Doosan’s strategy to optimise the The highlights of this latest availability and effectiveness of machining release include important new information on the shop- oor. features for rotary machining, adaptive turning, smart ■ Tebis ( www.is.gd/SCTexQ ) says one of measuring and multi-axis the features to support CAM automation machining. ( www.is.gd/Ydg6dZ ) with Tebis CADCAM is the use of the feature library - which is the way of ■ CAM automation is a key recognising the geometry data within principle for effective and ef cient CNC Doosan has integrated the ModuleWorks the CAD model. Once Tebis software programming while improving machining cutting simulation technology into its recognises the geometry data and quality, ef ciency and safety, and Tebis, Sketch Turn product assigns some basic attributes then, says one of the features that supports Tebis can start to add prede ned this with Tebis CADCAM software is the machining operations to machine the use of NCSets. ( www.is.gd/9lWtwL ) Technologies ( www.is.gd/VvzlOn ) offers geometries in the CAM programming a wide range of new functions for even process, explains applicant engineer ■ The new 2021.1 version of the higher surface qualities, primarily in tool Andrew Walters. hyperMILL CADCAM suite from Open Mind and mould making.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 27 CADCAM & PRODUCTION IT BOOSTING BOTTOM LINES
strategies we use means that we use a lot of ball nose tools for 5-axis cutting. “With hyperMILL, many of these strategies can be created in seconds. We also have a lot of like-for-like components come through our facility and we can overlay the models and use them as templates. This makes programming and setups ef cient to get up and running.” Mizen says the company is also adopting the Virtual Machine platform and the hyperMILL Optimisation Package from OPEN MIND. He says hyperMILL will now replicate the machine control, so it runs the NC programme rather than using POF les. It also provides fully “It is a ‘game- hyperMILL in use on the shop- integrated models in the fl oor at Multax Engineering changer’ for our simulation package, while the business and we now hyperMILL Optimisation have seven seats of Package looks at the tool Thomas Menholz, from 3D Concepts, says The Andover paths generated by the web shops are part of an overall digital subcontractor has 17 staff hyperMILL” software and creates strategy involving building blocks such as and has a business optimisations. RADAN CADCAM, MES, MRP and ERP all philosophy rooted in automated The catalyst for investing was coming together in an SQL-based system to production as ve of its six 5-axis the Covid-19 pandemic and the form a data-driven Smart factory. machines are automated, works in a Ventilator Challenge work the rm received, Trio’s key account manager Christian range of sectors including automotive, where it won an order for four different parts Weinberg, says that after logging into the web motorsport, aerospace, medical and scienti c totalling 31,000 that needed to be machined shop, customers can immediately upload manufacturing, but also worked on the within eight weeks. details of the parts they want manufacturing, Ventilator Challenge. Mizen says Multax developed its own using DXF, DWG or STEP les. Material, Director Ashley Mizen says: “It is a ‘game- xturing system utilising its 5-axis seven quantity, and additional operations are added changer’ for our business and we now have pallet GF Mikron machines and used the with just a few more clicks, and they receive seven seats of hyperMILL. We have hyperMILL job linking feature, reducing cycle their quotes within minutes – depending on integrated machine models. It is so simple to times from nine minutes per part to just over the size of the job. Then they can con rm the train a non-CAM user, we now have our two minutes. order, with a requested due date. setters and operators using hyperMILL as a McNab adds: “From a programming The workshop features an Amada EML- setting and programming tool. perspective, some of the biggest gains from 3610 NT combination machines, two Amada “It allows staff to check the datum of the hyperMILL are the time savings that come in Ensis AJ 3015 laser cutters equipped with part, produce the tooling sheet, put the NC terms of it being an all-in-one package where storage towers, and a number of Amada code into the machine and also run the you can do your design and manufacturing in press brakes. The parts run fully automatically veri cation software to prevent collisions. one ecosystem. We can also use the from the web shop to sorting after the cutting “Our team will always use hyperMILL for hyperMAXX strategies to push productivity process, without any manual intervention. everything from the simplest of parts to the and tool life to the maximum.” Depending on their complexity, folded parts most complex. From a business stance, it’s HyperMILL is helping get the best out of are programmed either automatically or great to have the simplest parts programmed machine tool technology: “We get real manually. After processing, the results are fed with hyperMILL as this means we have the bene ts through the simulations we have back from MRP to ERP. programs stored on our central server. whilst the graphical illustrations of the “If we get a repeat order, we can revisit machines allow us to get as close as we can GAME-CHANGER the programme, see what tools we have used to the table with the cutting tools.” Multax Engineered Precision Ltd is reaping and how the part is clamped, this gets us up Multax’s 10 machine inventory includes a the rewards from investment made in and running quickly. HyperMILL has been a Goodway GLS2000 turning centre and a hyperMill – the CAM software from Open revelation to our business, and we de nitely GLS2000LYS Y-axis machine. It has had the Mind Technologies ( www.is.gd/VvzlOn ) - as wouldn’t be where we are today without it.” hyperMILL turning package installed to the business continues to go from strength He adds: “We are a medium to high expand capabilities and help with more to strength. complex component supplier and the complex strategies. ■
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Preparing for machining at Arrowsmith
The Widia VSM890 has helped Sharpest standardise tooling on a door mount tools in the box
Most production engineers agree that any machined part is only as good as the cutting tools deployed. Steed Webzell rounds up the latest manufacturers to gain from new tooling investment
here are many elements to successful ve set-ups on a pair of three-axis machining CATERING FOR SUCCESS machining, not least the machine, centres and subsequently adapted the There are hardly any components or T program and workholding. However, the process to two set-ups on a single ve-axis products that will not bene t from the point of contact between tool and workpiece machine. The solution included the application of quality cutting tools, as a is particularly in uential in terms of process modi cation of the existing zero-point Merseyside manufacturer of stainless steel productivity and business pro tability. clamping system to add a secondary catering equipment can testify. When the With this thought in mind, most astute clamping plate and two Lang vices for company won a contract to manufacture machine shops are constantly scouting for holding these extra-long parts. stainless steel units for cruise ship galleys, tooling solutions that can provide that all- In terms of cutting tools for machining it asked Industrial Tooling Corporation ( www. important differentiating factor, one that can aluminium aerospace components of this is.gd/bakuku ) to help instigate productivity propel them ahead of the competition. type, MSC proposed the solid-carbide milling gains on door mount ttings. Coventry-based Arrowsmith Engineering, a range offered by SGS Carbide. Sharing the Before adopting ITC cutting tools, the prominent tier-one subcontract supplier to details of the project with SGS, MSC company was facing the 316 stainless steel leading aerospace OEMs, has found its own remotely created and optimised a selection blocks with a face mill, pro ling with a 90° formula to success through a partnership of cutting tools that would enhance indexable-insert cutter and nishing with a with tooling specialist MSC Industrial Supply machining performance and tool life, while solid-carbide end mill. The proposal by ITC ( www.is.gd/ufepam ). consolidating the number of tools required. was to apply the Widia VSM890 shell mill, With MSC supporting Arrowsmith over the By adapting the machining strategy to which would standardise the process to a past ve years to deliver cost reductions and just two set-ups, MSC has guaranteed single tool, rather than three. productivity savings of more than £500,000, process stability for critical aerospace ITC applications engineer Gary Murrey the subcontractor recently called upon its components with tolerances across the part says: “We wanted to double previous feed supply partner to provide support in the tied to less than 50 micron. MSC has also rate so that we could halve the cycle time. machining of more than 50 aluminium aero- instigated a machining strategy that is On the pro ling operation, this equated to engine components. yielding a cycle time for these complex parts running at near 0.11 mm/tooth at 1082 MSC reviewed the proposed strategy for of just 2 hours 20 minutes. rpm, with a feed rate of 600 mm/min and 4
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 31 TOOLING GET TO GRIPS WITH CHIPS
Tooling products mm depth of cut. For the facing operation we Of course, tooling is about far more than ran at 170 m/min cutting speed with a 430 cutting tools alone. Mapal ( www.is.gd/ in brief mm/min feed (0.08 mm/tooth) and 0.3 mm yinaye ), for example, has recently taken over cutting depth. tool management responsibilities at the “In the trial we reduced the milling Hitachi Automotive Systems Group in Poland, ■ For parting off at high feed rates, cycle time from 7 minutes and 30 Mexico and Turkey, which primarily EH geometry is now available from seconds to 3 minutes and 18 manufacture disc and drum brakes. By doing Horn. According to the company, seconds, and we standardised the so, Hitachi Automotive bene ts not only from the stable cutting edge enables feed rates in the range of 0.25 to tooling for this job,” he continues. tool management, but from opportunities 0.4 mm/rev during parting and “We also reduced the cost per edge provided by digital connectivity. grooving. www.is.gd/emiman from £2.40 to £1.50.” At Querétaro in Mexico, Mapal This success has since led to the implemented – and continues to implement – ■ Ceratizit Group’s Team Cutting Tools application of tools from ITC on other components from its modular tool has launched new variants of its projects at the company, which is a management system, including the hydraulic chuck range with VDI and theme replicated frequently Unibase-M tool dispensing system and a cylindrical shank connections. In throughout the machining sector: if Uniset-C setting xture. In addition, as in applications such as thread a cutting tool supplier does well, it Turkey and Poland, the Mapal service turning and ne boring, Ceratizit often leads to a long-term working includes a complete tool-setting area. says the chuck can reduce surface partnership. Another case in point “We make use of the whole service, from roughness by up to 70% compared involves Cambridgeshire-based the procurement of various consumables – with standard systems. www.is.gd/zimace subcontract manufacturer AJ Cook including cutting tools – through to the Engineering, which is taking advantage dispensing of materials and stock monitoring ■ Floyd Automatic Tooling has of tooling from MA Ford Europe ( www. with automatic re-ordering,” says Hubert introduced the UK market to the is.gd/olavig ) to meet customer Klehenz, Hitachi Automotive’s global newly developed MicroTurn eLine quality, precision and timescale sourcing director for braking systems. of boring tools from Ifanger. For demands, and optimise production producing small bores from 1.80 costs. OPEN-CLOUD PLATFORM mm in diameter, the MicroTurn In the interests of transparency and even eLine MTEE is more cost-effective than Ifanger’s existing MTEC or MTEN tools. EXOTIC MATERIALS more ef ciency, in 2019 Mapal enhanced its www.is.gd/hofi zo AJ Cook regularly manufactures products conventional tool management system and from aluminium, bronze and free-cutting now offers Tool Management 4.0 via an ■ High cutting pressure, tool de ection and steel. However, the company’s Haas milling open-cloud platform from c-Com GmbH. wear are particular challenges when it and turn-milling machines are usually set to “Tool Management 4.0 has de nitely comes to thread milling. Overcoming these work on more exotic and harder materials, given us a boost when it comes to issues formed the basis for developing such as Inconel and various grades of digitalisation and its bene ts for machining,” Walter’s new TC620 Supreme solid-carbide stainless steel. says Klehenz. “For instance, we now have thread-milling cutter. www.is.gd/huyivo “It was just after we purchased our signi cantly more exibility when replacing second Haas that MA Ford Europe was tools, which means less downtime.” ■ ■ The new Guhring RF100 Micro Diver end recommended to us by a customer,” says mill provides plunging and milling in a single joint managing director Alistair Cook. “We tool. According to the company, the end mill wanted to improve productivity and tool life, permits extreme cutting data with high without compromising quality or nish, on cutting depths. www.is.gd/izixas dif cult-to-machine materials.” Trials compared MA Ford’s coated solid- ■ Kennametal has a newly developed carbide end mills, thread mills and turning line of PCD round tools for aluminium tools with AJ Cook’s existing tool solutions machining, with the company and other brands. The results showed not reporting up to 10 times only were production times cut in half, but higher productivity than tool life more than doubled, which had a carbide tools. signi cant impact on reducing the monthly www.is.gd/ruzumu tooling cost. “There are a range of areas where MA An employee measures a special disc milling Ford excels, and their tooling is signi cantly cutter from Mapal - image courtesy of Hitachi ahead of anything we’ve evaluated for harder Automotive Systems materials,” says Cook.
32 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets PRECISION MEETS INNOVATION THE NEW VLASER 270 BY VOLLMER
With the new VLaser 270, VOLLMER has introduced a complementary step-change in technology. In addition to the portfolio of grinding and erosion machines, VOLLMER has now introduced laser technology for fast, efficient and high-quality machining of ultra-hard materials such as PCD, CVD- D and MCD. Providing the highest possible flexibility, quality nda surface finishes to your cutting tool production. New solutions combined with reliable precision: Simply VOLLMER.
VLaser 270 www.vollmer-group.com Tool Sharpening Machine VOLLMER UK LTD. // Nottingham NG10 5BP // +44 115 9491040 // [email protected] Rising demand led Ondrives to invest in the advanced Studer S31 cylindrical grinding machine
Precise purchases for high performance
Ondrives adds a second Studer cylindrical grinding machine to meet demand; Marlor invests in a Rollomatic Shapesmart as it moves into the medical sector; Danish tool manufacturer puts trust in Vollmer; plus, news and products briefs
urging demand at Chester eld-based between centres grinding capacity from The Studer S31 purchased by Ondrives is Ondrives has led the precision gear 400mm to 1000mm. The advanced new designed for the individual, small-batch, and Sindustry player to ramp up its machine boosts the ef ciency of its large-scale production of short to long-sized machining capabilities by adding an advanced precision grinding work. workpieces. The S31 has a centre height of Studer S31 cylindrical grinding machine, Managing director Ben Hinchliffe explains 175 mm and is available with between supplied by Micronz ( www.is.gd/HBMXi3 ). the Studer S31 was slightly more expensive centre options of, 400, 650, 1000 and The company manufactures high than other machines it looked at but was the 1600 mm. precision gears and associated components most “technically capable option”. He says A solid Granitan base forms the to demanding levels of dimensional, to satisfy its challenging requirements, the foundation, guaranteeing maximum levels of roundness and surface- nish speci cations advanced Studer S31 cylindrical grinding precision, performance and reliability. The from it 3200 square metre facility, but machine was speci ed with the addition of cushioning characteristics of the S31’s needed to increase high precision internal, several advanced options including a machine base helps to ensure the external and thread-form grinding capacity to synchronous driven tailstock. outstanding surface quality of ground keep up with an ever-growing order book. “This enables our operators to complete workpieces and also increases the service Ondrives has used a Studer S21 grinding work in a single set-up, rather than life of grinding wheels. cylindrical grinding machine since 2011 and making multiple changeovers. The Studer Reduced set-up and resetting costs, decided to invest in a second model as it S31 has more than doubled our between- especially in single-part or small-batch was impressed with the performance. centres grinding capacity, increasing our production, are made possible by the S31’s When compared to the existing S21 precision grinding capabilities and this has turret wheelhead with several grinding model, the Studer S31 cylindrical grinding signi cantly raised our ef ciency levels,” wheels. Users’ ef ciencies are further machine has increased the company’s adds Hinchliffe. boosted by the ability to perform complete
34 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets GRINDING, HONING & SURFACE FINISHING MACHINE MOVES
machining in a single clamping. TRANSFORMING PRODUCTION Cross states the quality, surface nish and The S31’s swivelling wheelhead is Marlor Tooling has entered the medical tool repeatability from the machine is “stunning”, equipped with water-cooled, roller-based, and instrument markets for the rst time by while the extended wheel life and dressing maintenance-free motor spindles with purchasing a Rollomatic Shapesmart CNC frequencies have been a “revelation”. stepless speed control and the latest tool grinding machine, supplied by Advanced Cycle times have been dramatically generation of contact sensors. The shaft Grinding Supplies ( www.is.gd/OQN5uZ ). reduced with Marlor siting another example ends hold external wheelheads with a The Peterborough-based cutting tool of a long length through-coolant drill for an diameter of 500 mm and a width of 63 (80 manufacturer is located in a state-of-the-art aerospace application that used to take F5) mm. For internal grinding, powerful high- production facility and also has 12 CNC tool them seven mins to manufacture as frequency spindles are used. and cutter grinding machines, plus various compared with a new time of just two The machine’s versatile universal other CNC machines including EDM, drilling minutes on the Rollomatic machine. workhead enables both live spindle grinding and inspection machines. Nearly all of In quantifying improvements in quality and grinding between centres and is Marlow Tooling’s sales are to other tool Marlor has found the Rollomatic machine equipped with roller bearings and has an manufacturers and they sell directly to very easily holds tolerances of under 3um on tool excellent roundness accuracy of under few end users of tools. diameters over larger batches of tools and 0.0004 mm, which can be optionally Works director Martyn Cross says after previously they simply couldn’t achieve that. improved to under 0.0002 mm during live identifying a production bottleneck they Rollomatic’s ShapeSmart machines are spindle operations. looked at many CNC cylindrical grinding designed for grinding tool blanks and similar Grinding of shapes and threads is made machines over the last three or four years stepped cylindrical components and based possible by the position and speed- with the need for fast set-up times and on the method of peel grinding; a technology controlled C-axis. The C-axis features an exibility to make high precision tools, invented by Rollomatic. This new generation indirect measuring system on the drive before opting to purchase their Rollomatic of cylindrical grinding machine has been motor and is suitable for thread grinding and MP3+ machine. improved to offer more advantages for fast simple form grinding. For maximum form According to Cross, the set-ups and superior grinding quality accuracy, a direct measuring system is Rollomatic NP3+ is one including both rough and nish grinding in a mounted on the workhead spindle (high of the “most single automatic operation for accuracy C-axis). transformative diameters up to 25mm with a The addition of a synchronous driven machine purchases Renishaw probe handling length tailstock on the Studer S31 allows the that Marlor has positioning. complete machining of workpieces in a ever made”. The NP3+ has contributed to a single set-up. As this bene cial option helps Small or large to avoid complex changeovers to additional batches of tools operations costly downtime is eliminated are now all done in- The Rollomatic machine has enabled and impressive ef ciency gains are house with precise Marlor to enter into the medical tool achieved. surface nish and blanks market for the fi rst time The 90mm travel of the S31’s tailstock holding the tightest of barrel simpli es the changeover to a new tolerances. workpiece, whilst component families can be The machine has enabled Marlor to quickly set-up with minimal effort, leading to enter the market for medical tool blanks further productivity increases. for the rst time, enabling it to secure The S31’s synchronous driven tailstock several high value orders, including the increases dimensional accuracy related to one shown with the rst batch of tools form and positional tolerances on the ground being 300 off that was produced workpiece, enabling the most challenging of automatically using the Rollomatic’s quality requirements to be met. It is fully integrated robot loader. hydraulically operated and equipped with an Cross says it is “delighted with the electronic measuring system which allows quality achieved” that was well within simple readjustment. Both closing speed the desired tolerances across the entire and positioning speed can be adjusted batch of medical parts with cycle times individually with control valves. from the solid bar being under eight The S31 is equipped with a Fanuc 0i-TF minutes. and the machine’s portable control unit Marlor is able to fully utilise the easy (PCU) enables set-up close to the grinding to set auto loader during the evenings process, while complementing the machine and nights whilst manufacturing lower is the StuderWIN software. quantity special tools during the day.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 35 GRINDING, HONING & SURFACE FINISHING MACHINE MOVES
Værktøjsslibning (TN Slib) to put its trust in Using the VGrind 340S grinding machine, Vollmer ( www.is.gd/nKB13P ) after purchasing TN Slib seeks to drive forward the a VGrind 340S tool grinding machine. development and production of small milling The company employs 25 people, who cutters and somewhat larger drill bits with produce, coat, solid and resharpen solid diameters of between 0.3 and 8mm. Delicate carbide tools such as milling cutters and drill tools like these are facing increased demand bits in a workshop 50 kilometres from in the manufacturing industry because of the Copenhagen. TN Slib specialises in ever-tighter spaces encountered in mobile developing bespoke stepped milling and devices, medical equipment and automotive drilling tools in close collaboration with its technology. customers. Vollmer designed the VGrind 340S Currently, its customers hail especially for machining small solid carbide primarily from Europe, but is cutting tools. With its two vertical spindles for attracting ever-increasing interest different grinding wheelsets, the grinding from businesses from further machine allows for multi-level machining. This a eld. Founder, owner and CEO enables TN Slib to cut down on non-productive says Torben Nielsen says the time and further improve tool quality. Five Above: The Timesavers 12- company sees great potential in optimally con gured CNC axes achieve 600-W deburring and fi nishing the collaboration with Vollmer, interpolation with short travel distances for machine from Ellesco in both now and in the future. the linear and rotational axes, which in turn action TN Slib makes around three-quarters of its reduces the time required to machine Above right: Andreas Hohmann, MD sales in the production of bespoke, solid workpieces and allows for incredibly tight tool at Total Carbide, and Ian Meredith, carbide tools. The company also offers tolerances. applications engineering manager at Master Abrasives standard tools for cutting metals such as A key factor in TN Slib’s decision to steel, aluminium, cast iron or copper with purchase the VGrind 340S was the machine signi cant saving on production lead times, customers across the medical technology, has the versatility to produce both small and allowed rapid response for urgent jobs aerospace and automotive industries. large batches. The NUMROTOplus software needing CNC cylindrical grinding, helping To improve the performance and operating enables three-dimensional simulation of bring in all manufacture of tool blank life of its tools, TN Slib coats them using two production processes and makes it possible grinding in-house. dedicated coating machines. A new CNC to carry out collision monitoring in advance. To milling centre was procured speci cally to test allow the company to operate the grinding HIGH POTENTIAL different coatings. Around ve per cent of the machine around the clock, tool manufacturer A need for greater quality and precision has company’s sales come from its resharpening TN Slib opted for an optional automation led Danish tool manufacturer TN services. solution. ■
News and products in brief
■ Engis ( www.is.gd/VpuP1f ) superabrasive single-pass bore ■ Oldham-based the Constant Group, which provides full design nishing offers high precision tolerance in a large-scale production to manufacture service that encompasses its own products, has environment for many hydraulic and automotive honing applications. invested in Timesavers 12-600-W deburring and nishing machine Development over many years has led to signi cant advances in from Ellesco ( www.is.gd/BVNZCw ). bore size, geometry and customisable surface nish - so much The machine can be speci ed with working widths of 225 mm or so that bore size control has now reached the limits of current air 600 mm and has made a signi cant impact on the ef ciency when gauge capability. graining stainless steel materials.
■ Gloucester-based Advanced Grinding Supplies Ltd ( www. ■ Master Abrasives ( www.is.gd/5abGwM ) has installed a Micromatic is.gd/3tWDyF ) has been appointed as the exclusive agents in the Pluto 18 machine at Total Carbide, a manufacturer of sintered UK and Ireland for both Meister Abrasives and Alfons Schmeier Tungsten Carbide wear parts based near Aylesbury. Abrasives, further expanding the rm’s grinding-related offering. Pluto-18 is a specially designed by Micromatic Grinding Meister Abrasives offers a broad range of abrasive solutions, Technologies to focus on compactness, high performance and while Schmeier Abrasives provide internal grinding wheels and provide an economical grinding solution. It is best suited to produce ne grinding media made of CBN, diamond, silicon carbide and highly accurate small components and can perform both plunge and corundum in a ceramic bond. traverse grinding operations.
36 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets THE ART OF GRINDING. BECAUSE PRECISION IS CREATED UNDER A KEEN EYE.
Fritz Studer AG, established in 1912, is a market and technology leader in universal, external and internal cylindrical grinding as well as noncircular grinding. With around 24,000 delivered sys- tems, STUDER has been synonymous with precision, quality and durability for decades. studer.com
The Art of Grinding. A member of the UNITED GRINDING Group The Mitsubishi MV1200S in operation at Raysun
Wired for Pemberton Engineering is enjoying 25% more throughput thanks to a productivity Sodick wire EDM machine
A number of notable recent installations are demonstrating the provide customers with even better service and support,” explains managing director enduring appeal of wire EDM, which has much to offer OEMs, Darren Pemberton, who uses the word subcontractors and toolmakers alike. Steed Webzell has the details “buoyant” to describe current business levels. “Having looked at the leading wire ccuracy and surface nish aside, wire which is enjoying 25% more throughput since EDM models in the capacity range required, EDM retains its popularity for many investing in new Sodick wire EDM the Sodick VL600Q was the obvious choice. Areasons, not least its ability to technology. The introduction of a VL600Q Particularly attractive was its 25% increase machine parts and features beyond the from Sodi-Tech EDM ( www.is.gd/zonehe ) at in speed over our existing machines.” potential of conventional machining the company’s Wolverhampton facility is The VL600Q, with its travel in the X, Y methods, and its suitability for hardened and boosting productivity in the manufacture of and Z axis of 600 by 400 by 270 mm, exotic metals. Of course, wire EDM press tools, jigs and xtures for tier-one and features linear motors that provide high- technology is subject to ongoing tier-two automotive suppliers. speed motion and quick response times. development, which is why regular “Beyond our single shift pattern, the investment in the latest machines can pay MAJOR BOOST VL600Q is already running lights-out real dividends. “Although we were already running two wire overnight and at weekends, and has totally Among those discovering the virtues of EDMs, we knew that another would deliver a eliminated bottlenecks within our work ow,” this strategy is Pemberton Engineering, major boost to operations and allow us to says Pemberton. “At present, the machine is dedicated almost exclusively to punch and Getting the measure of EDM die work, as well as forming steels for press tools – all for the automotive sector. Smethwick-based A&M EDM, one of the The fact that one of A&M EDM’s Everything is made from tool steel.” UK’s largest subcontract EDM companies, major aerospace customers has multiple Further east along the M6 corridor is the has invested in a Crysta-Apex V CNC CMM Mitutoyo CMMs, aided the company’s Rugby facility of another rm with expertise from Mitutoyo ( www.is.gd/haloca ), which investment decision. in toolmaking: Raysun Innovative Design. offers a capacity in X, Y and Z of 900 by “The impressive speed and accuracy The production facility of this end-to-end 1000 by 800 mm. speci cation of our new CMM – as precision engineering, design and A&M quality inspector Steve Foster corroborated by our customer – has manufacturing business specialises in jigs, says: “The Crysta-Apex V was the most up removed the potential for delays in our xtures and tooling for the aerospace to date and advanced CMM of the three inspection department and is now helping industry, and has seen the introduction of its machines that we considered, and the to ensure the quality of our output,” states second Mitsubishi wire EDM machine, a most suitable for our needs.” Foster. MV1200S model, from the Engineering Technology Group ( www.is.gd/gozupi ).
38 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets EDM & ECM INVESTMENT PLANS SPARK INTO LIFE
Director Charles Ray says: “We For 90% of its time, gear production is purchased a second Mitsubishi because we the main activity on the Makino U6 H.E.A.T., had a good experience with our rst one, the principally the wire cutting of keyways in larger MV2400S. This rst machine was a hardened steel. bit of a chance for a small business like “Due to our rapid growth, we previously ours, buying a ‘top-end’ machine tool. had a shortfall in EDM capacity and were However, we soon found that we were using constantly running behind with orders, but it for all kinds of applications that at rst that situation has changed dramatically,” didn’t appear obvious.” says Baines. Hopwood Gears’ operations director Calum Before the arrival of the MV2400S and He says that the Makino U6 H.E.A.T. Baines with the Makino U6 H.E.A.T new M1200S, which gives travels of 400 by uses 30% less wire and is 30% quicker at 300 by 200 in X, Y and Z, the company cutting than the other EDM machine on-site. admits it had very limited previous This speed is thanks to a combination of knowledge of EDM. machine rigidity and two large, high-pressure “The toolmakers we employ have a ushing pumps that can evacuate chips background in milling, turning and grinding,” ef ciently, pushing the wire harder. says Ray. “I wouldn’t say that EDM is a black art, but we rely heavily on the CNC MICRO-HOLES units. The CNC allows us to enter elds such Another notable trend is the growing use of as material, pro le type and number of cuts, EDM technology to produce holes, after which the machine selects the particularly micro-holes like those optimum strategy.” commonplace in diesel fuel injectors. Adds Ray: “I’m not a programmer myself, Among the manufacturers investing in a but my colleagues tell me the control is solution of this ilk is US-based Dynomite considerably upgraded from the previous Diesel Product, which is achieving both The Mitutoyo Crysta-Apex V was selected by version on the MV2400S.” higher precision and lower cost when A&M EDM ahead of two other CMMs producing high- ow injectors thanks to its STEPPING UP A GEAR new ONA MF5 micro-hole EDM machine. features a C-axis rotary table and head-tilt Of course, wire EDM has many uses outside By integrating the ONA MF5 into the capability. the realm of toolmaking, with Oldham-based production process (alongside an extrusion Lenny Reed, owner of Dynomite, says: Hopwood Gears a case in point. To boost machine), Dynomite has managed to reduce “The machine enables us to remain abreast production capacity, the company recently its manufacturing time to less than ve of the ever-changing requirements of this installed a Makino U6 H.E.A.T. wirNeile EDM minutes (from two hours). sector. Moreover, we can predict more machine from NCMT ( www.is.gd/xeseta ). Furthermore, the new procedure makes accurately the time spent on each product, “We rst became aware of the supplier when nal calibration much faster and more which helps with costings.” we attended a gear seminar at their Coventry consistent, injector-to-injector. The ONA Reed says the costings are very good, technical centre,” says operations director MF5, which is available in the UK from CNC which bodes well for the future as the Calum Baines. “The level of technology and International ( www.is.gd/agifi z ), offers 150 company is anticipating a useful machine machine build quality was impressive.” by 150 by 150 mm travel in X, Y, Z and life of circa 20 years. ■ EDM & ECM news and products in brief
■ Betterbrass – a next-generation special alloy brass wire launched streamline and enhance the route to market for Winbro solutions recently in the UK by Erodex ( www.is.gd/fohili ) – is helping users and provide added accessibility for customers. Winbro, which to increase cutting speed by up to 10% in early trials. Among has a UK manufacturing facility in Coalville, specialises in non- the early adopters of the technology is Halesowen-based HLP conventional machining processes that include high-speed EDM Engineering Solutions. drilling and ECM. www.is.gd/uwopem Director Luke Hobbs explains: “We found that Betterbrass is excellent on threading and, for the small increase in cost, offers ■ GF Machining Solutions ( www.is.gd/zuredi ) has supplied speed improvement of around 10-12% over standard brass wire Hersham-based Fimark with a new AgieCharmilles LASER P using the same settings.” 400U laser 3D texturing machine, helping the company to further develop and exploit new application opportunities in this emerging ■ Winbro Group Technologies has commenced a partnership market. The machine can accommodate workpieces measuring up with the Engineering Technology Group. The new agreement will to 600 by 400 by 250 mm.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 39 Cost-effective & precise machining for medical
Q&A with Brian Edmondson, area sales manager for Yamazaki Mazak in the Midlands
What trends are you seeing that are with extremely hard-to-cut metals such as single jobs, while also capable of providing Qdriving innovation in machining titanium, chrome alloys and stainless steel, large quantities of high-volume repeat parts centres for the medical sector? so innovation has been ongoing to provide with unerring precision. The needs of manufacturers working in machining centres with a very rigid platform In particular, there has been a focus on the medical sector can vary widely, with a and stable trunnion table to meet this developing the use of technologies, such as combination of capabilities being required need. Mazak’s own Smooth Control CNC solution, from multi-tasking to 5-axis work. However, Alongside this, extreme accuracy and that allow the more intuitive operations and on the whole, we have found that precision is required when working with easy editing of machine programs required companies in this eld are looking for a these metals, which can be processed for to achieve this goal. combination of factors from their machining components as diverse as the elements of Finally, the medical sector is extremely centres. orthopaedic devices, to dental implants competitive, so being able to implement the These include an extremely high degree and surgical tools. Of course, given the automation solutions required for round-the- of accuracy and repeatability, a rigid applications these machined parts are clock shift working can provide business machine platform to used for, a high-spec nish is expected as with a vital competitive edge in an achieve a high-quality standard. increasingly crowded market. surface nish, suf cient When considering the purpose of the Indeed, automation is a key driver across spindle power for components that make up a hip joint, for all sectors Mazak works in, including dif cult-to-cut materials, instance, it is also clear that a one-size- ts- medical, and ease-of-integration with and a design that can all approach will not suf ce. Instead, a high automation systems has played a be easily integrated with degree of customisation is required signi cant role in the R&D process for automation technology. depending on the individual’s height and Mazak’s most recent product launches. In the rst instance, posture. it is clear that many As a result, innovation has been driven How is Mazak technology helping companies working in the toward creating adaptable machining Qcustomers meet their wider and day- medical eld will work centres that can provide extremely accurate to-challenges in the medical fi eld?
40 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets MAZAK MEDICAL CAPABILITIES
This coupled with the intelligent Thermal Shield system that maintains stable cutting accuracy by applying automatic compensation to combat temperature uctuations, along with linear roller guides that provide a dampening effect and ball screw core coolant that helps maintain high accuracy, combine to deliver extremely precise 5-axis machining over multiple cutting mediums. Interference is further reduced due to the spindle cartridge’s narrow design, which allows the spindle nose to reach the middle of the table, minimising the potential for disruptive vibration. Finally, the CV5-500 is designed to Automation is a key driver for all sectors enable easy integration of automation Mazak works in, including medical, and systems, thanks to the addition of its B-axis has played a big part in the company’s most table and side-loading door, which also 5-axis recent product launches conveniently allows tools to be replaced in automatic cycles. Due to this compatibility, manufacturers can quickly realise the around-the-clock unmanned 5-axis machining required to remain competitive applications as medical component suppliers. Crucially, operators can then be deployed elsewhere in the manufacturing Speaking to stakeholders within the provides companies, such as those plant for further operational ef ciency, but medical eld, we have increasingly found a manufacturing for the medical sector, with as the front of the machine remains gap in the market for a fully-simultaneous the ability to easily incorporate 5-axis uninhibited from automation equipment, and competitively priced 5-axis machine. machining into their operations, at a they retain convenient access for setups The general feeling has been that competitive price point, without having to with full visibility of the machining operation companies have to choose between price compromise on rigidity, accuracy or quality. at all times. and precision – that is, a lower cost leading Consequently, these organisations can To nd out more about Yamazaki to a lower standard of machining. carry out high-spec machining at a Mazak’s CV5-500 machining centre, visit Conversely, any solution that can best comparatively lower cost than previous ( www.is.gd/xmIkVi ). For further information guarantee micron-accurate 5-axis machining associated with 5-axis solutions. on the machine offering to the medical will naturally come with a prohibitively It is for this reason that we think the sector, visit ( www.is.gd/nMvRpl ). ■ expensive price point. CV5-500 resets the bar for the compact However, in a market where precision 5-axis machining category and delivers a can directly impact quality of life, it is clear new benchmark for both British and there cannot be compromise insofar as European machine tools. accuracy is concerned. On the other hand, the events of 2020 have impacted capital What is unique about the CV5-500 for expenditure budgets across all sectors, Qmedical applications? leaving manufacturers potentially unable to A key strength of the CV5-500 is its high- expand their machining capacity and rigidity bridge construction with a fully capabilities in this competitive eld. supported trunnion table, which allows for the With these twin factors in mind, we extremely accurate machining that makes it developed the compact CV5-500 5-axis unique in its category. It is equipped with a machining centre – the only Mazak machine 12,000 rpm spindle, with an option for in its class to be completely conceived, 18,000 rpm, capable of a peak performance designed, and built in the UK, at our of 18.5 kW and 119.4 Nm, making it suitable European Manufacturing Plant in Worcester. for the range of demanding materials required Central to the CV5-500’s appeal is that it in medical application machining.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 41 COMPOSITES MACHINING CUTTING TIMES
Composite collaboration exceeds expectations A Czech Republic collaboration has developed a new hybrid metal and carbon fi bre composite milling cutting disk utilising a Doosan machining centre
Doosan Mecatec HM63H machining centre. maximum weight limit. This was not achievable The distributor of Doosan machines in the UK using four conventional metal disc cutters, & Ireland is Mills CNC ( www.is.gd/OIjyom ). which each weigh 7.93kg. The milling operation to accurately cut to To further boost machining performance, tolerance the side and the bottom faces of the the novel hybrid tool design included additional forged link was completed in 10 seconds cutting inserts per disc. The hybrid milling tool using the new four-disc hybrid milling cutter, has 64 cutting inserts on four discs compared 35 seconds faster than the two-disc metal with only 24 on a two-disc milling cutter. tool. Measurements made for both types of milling tools showed the hybrid CF four-disc LIGHTWEIGHT COMPOSITE Doosan HM63H (image courtesy milling cutter had a 50 per cent faster cutting The new hybrid tool design uses a lightweight of Craig Strong Machine Tools) speed and a 54 per cent higher feed rate. Tool epoxy composite with ultra-high modulus life durability data recorded 250 pieces carbon bres for the inner section of the zech Republic-based rms CompoTech machined before a tool change for the two-disc individual milling discs. and Hofmeister have collaborated to milling cutter, compared with more than 1200 The proprietary continuous bre Cdevelop a new hybrid metal and carbon parts using the new hybrid four-disc tool. manufacturing process developed by bre (CF) composite milling cutting disk CompoTech enabled the production of fully reducing machining times by 78 per cent. ADDED BENEFITS integrated hybrid milling discs with an outer The new milling tool project was initiated by Key production bene ts of the new hybrid four- band of 16 metal cutting inserts. Hofmeister, an engineering company disc milling tool included lower inertia moment, The semi- nished CF composite specialising in the development of complete resulting in lower energy consumption cost components for the hybrid discs were machining technologies after receiving an savings, lower thermal-mechanical load on produced and assembled by CompoTech using inquiry for a four-disc milling tool from a milling machines, better anti-vibration damping semi- nished steel components supplied by leading European chain manufacturer looking properties, increasing slot hole machining Hofmeister. The nal machining of each hybrid to improve output rates and reduce production accuracy, smoother machine operation, cutting disc and assembly of the complete costs. enabling higher quality surface nish, and hybrid milling tool was also carried out by By using CompoTech’s carbon bre signi cantly increased output rates Hofmeister. technology in the design and production, a new and productivity. The entire four-disc hybrid lightweight CF composite and steel hybrid An added cost milling cutter weighs only milling tool was successfully developed with bene t for 16.25kg, well within the two additional cutting discs. manufacturers is the maximum 25kg tool weight With an initial target of a 50 per cent cutting edge durability limit of the BT50 L 150 mm reduction in overall machining time, the nal of the new hybrid tool, master mandrel on the Doosan design exceeded the goal. The hybrid four-disc which has 40 extra Mecatec HM63H. milling tool increased the cutting speed and cutting inserts, is The hybrid four-disc milling feed rate and is 78 per cent faster on the almost ve times cutter tool offers manufacturers same milling centre than a standard steel two- greater. the opportunity to save time and disc cutter. The new four-disc hybrid money by achieving signi cantly higher Test milling of the 200mm diameter four- tool was well within the speci ed unit output volumes using existing CNC disc hybrid tool by was carried out on a forged Doosan Mecatec HM63H twin pallet milling centres, with lower overall production high-strength steel connecting link using a horizontal machining centre’s 25kg costs. ■
42 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets CUTTING OILS & COOLANTS QUALITY CONTROL
Helping achieve optimum performance recision machining subcontractor Investment in Rocol cutting fl uid solutions proving benefi cial to manufacturer and workholding Brown & Holmes; Q8Oils boosting Twifl ex; and Total launches new Pspecialist Brown & Holmes is gaining bene ts from cutting uid solutions for Rocol BioLife range ( www.is.gd/XPrajB ) to keep its machine shop running at optimum levels, emphasising how work closely with prestige companies like within the machine envelope and the wider key an effective cutting oil is to machining Rolls-Royce. We have been using Rocol work area; this is not the case with the productivity and quality. uids for almost 10 years now and their Rocol uid. Our shop- oor team have also The Staffordshire-based rm supplies products are excellent. We have a great noticed a difference with the smell in the services to blue-chip companies and Tier 1 relationship with Rocol and if we machine shop. There used to be an suppliers throughout the UK, Europe, Asia have any concerns regarding our The odour in the machine shop from and the US, delivering machining services to uids, they are immediately our cutting uids, but this is the automotive, aerospace, machine tool, on-site curing any problems Rocol Ultracut EVO now a thing of the past,” he construction, and nuclear industries. we may have.” 250 demonstrates a adds. The rm’s plant list includes milling, Applying the Ultracut As a manufacturer with turning, grinding, jig boring and grinding, 3D EVO 250 long-life soluble noticeable a huge emphasis on printing and wire erosion, utilising machines cutting uid throughout the difference with environmental sustainability from XYZ, Mazak, Doosan, Myford, Jones & Tamworth site, Gulliver and employee health and Shipman, Colchester, Sodick and others, to explains: “The Ultracut EVO evaporation wellbeing, the application of machine a diverse range of materials. 250 is excellent and it has made Rocol Ultracut EVO 250 is The challenge it says with such diversity a signi cant improvement to our tool paying dividends for Brown & is selecting a suitable cutting uid that can life. We have used various other products in Holmes. Suitable for use with a diverse perform on all types of machine tools and the past, but the performance and longevity range of ferrous and non-ferrous materials, materials – this is where it explains that of the Ultracut EVO 250 uid are signi cant, Ultracut EVO 250 provides a long and Rocol steps in. it makes a very clear impact on our tool life predictable sump life and is installed As a company that places quality and performance – increasing our tool life and throughout the machine shop at Brown & environmental sustainability at the top of its cutting data signi cantly.” Holmes. priority list, Tamworth-based Brown & This prolonged sump life and the Holmes is an ISO: 9001, AS: 9100D, ISO: EVAPORATION GAINS elimination of shop oor odours is down to 14001 and OHSAS: 18001 certi ed With the ever-increasing introduction of high- several factors. Firstly, the high performance manufacturer. With such an emphasis on speed machining and the onset of coolant uid rejects tramp oil which when removed/ quality, selecting the right cutting uid is evaporation, Gulliver explains that as well as skimmed off eliminates the main food essential. improving machining performance, the Rocol source for cutting uid born bacteria. The Brown & Holmes CNC programmer Ultracut EVO 250 demonstrates a noticeable uid itself is inherently resistant to Michael Gulliver says: “We are a global difference with evaporation. degradation thanks to the biostable makeup precision workholding company and we also “Previous uids would easily evaporate of the product.
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 43 CUTTING OILS & COOLANTS QUALITY CONTROL
world-class cutting uid service engineers do it all for us. They will inform us package, Ultracare service of any problems, and they will resolve them engineers have been extensively immediately to ensure our uid is always in trained in the care and prime condition.” maintenance of cutting uids to The Ultracare service provided to Brown & keep uids in optimum condition. Holmes sees engineers checking machine This service includes a unique tools every month to ensure optimal customised care and machining conditions are always maintained. maintenance programme that This service includes the checking of ensures all cutting uid everything from the materials being requirements are achieved. machined and the cutting tool consumption The productivity results of the to initially determine the most suitable uid Ultracare service are reduced for the respective machine and application. uid consumption, extended tool With UK laboratories based on the life, reduced machine downtime outskirts of Leeds, Rocol will test existing Above: Q8Oils installed a MicroMag to and signi cantly reduced waste disposal uids and neat oils in the machine tool bolster Twifl ex's fi ltration system costs – all factors acknowledged by Brown & before recommending a solution. This Also, it contains no biocides or skin Holmes. Plus, Ultracare service helps includes performance, bacteria and fungal sensitisers which makes this particular towards HSE compliance and provides a tests. cutting uid very operator friendly. Ultracut safer working environment for all Brown and Once a machine has been lled with EVO 250 is suitable for both individual or Holmes employees. Rocol uid, the Ultracare team regularly centralised cutting uid systems and it is Gulliver concludes: “We have Ultracare conduct site visits that encompass both pleasant and safe to use. However, engineers that come to us every month – everything from uid levels, dilution rates, what sets Rocol apart from its rivals is the and we nd this very comforting. It gives us pH levels and complete reporting with a Ultracare service and support. peace of mind that the product is being programme that has been tailored to each With experienced Ultracare service looked after and it is one less thing that we end-user with all recommendations and engineers that cover the UK to provide a have to worry about or check on, as ROCOL corrective action undertaken. ■ News and products in brief
■ Twi ex designs and manufactures advanced braking technologies largely extended. An improvement in uid cleanliness was also noted for industrial applications and it is imperative that the nished that in-turn had prevented the ‘ ecking’ effect caused by ne debris products, such as their industrial brake discs are made to the highest caught between the wheel and the workpiece during the grinding possible standard and it has been boosted by investment in products process. by Q8Oils ( www.is.gd/VTulLo ). While their current process was working suf ciently, the rm was ■ The special uids business unit of Total ( www.is.gd/YiLctv ), a major exploring new methods to improve the productivity of their grinding producer of hydrocarbon uids for industry, has launched BioLife, a machine that grind both cast iron and steel. new range of renewable, pure and biodegradable isoparaf ns, to the Other ltration methods, such as paper lters, can offer an UK marketplace. effective barrier against larger particles, they can allow for smaller Developed in response to calls from industry and consumers for ferrous particles to pass through with the uids which can lead to a more sustainable and environmentally friendly products, BioLife is a signi cant reduction in tool life expectancy. range of bio-based hydrocarbon solvents which provides a safe, In addition to the use of their Berlioz XRS synthetic grinding uid, sustainable and odourless alternative to traditional fossil-based Q8Oils installed an Eclipse Magnetics MicroMag MM20 in-line, prior solvents. to uid delivery, to bolster the ltration system of Twi ex’s grinding BioLife can be used in a wide range of applications such as machine. With its high-intensity magnetic core and patented uid ow inks, paints & coatings, cleaning, degreasing, personal care, home path, the MicroMag captures almost all the of ferrous contamination care, heat transfer media, lubricants and hydraulic and from metalworking uids. metalworking uids. The range also boasts a compact and easy-clean design with a The use of patented high-pressure hydrogenation HDA high-capacity collection that does not block the through ow, nor does technology coupled with narrow cut distillations, means BioLife it impact the pressure or ow of the uids. products are tailored for targeted applications with narrow boiling Having had the MM20 installed at Twi ex for one month, with range, offering pure solutions with ultra-low aromatic content. intermittent usage, the lter had caught over 2kg of ferrous materials BioLife is colourless and odourless, has a low pour point and a when removed for cleaning. high ash point and is classi ed as “readily biodegradable”. Total Q8Oils also reported Twi ex has seen a substantial improvement says the range gives customers an opportunity to “reduce their to the grinding stone life, with the frequency of grinding wheel dress environmental impact without compromising on performance”.
44 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets MEDICAL SECTOR GLOBAL SOLUTIONS
Starrag Bumotec machines are boosting productivity at Shanghai Medical Instruments Making the difference
Starrag Bumotec machines boost operations at Shanghai Medical Bumotec machining centres (models s192, s181, s191). The rst was installed in 2005. Instruments; medical industry subcontractor benefi ts from investing A range of 500 different types of minimally in CADCAM software; and new recyclable visor to fi ght Covid-19 invasive and ENT instruments are machined secures key approval in a single set-up from bar on the Bumotec machining centres. It was found that ‘conventional’ separate machine were not he global medical sector has been one faceted components from bar up to 65 mm able to produce these components of globe’s growing sectors during the diameter, and with up to seven-axis effectively, especially in terms of consistent TCovid-19 pandemic and a trio of Starrag simultaneous machining in a single set-up, quality of the relationships of ‘matching’ ( www.is.gd/VsGcno ) Bumotec multi-axis, Bumotec machining centres are capable of parts. The multiple complex clamping multi-tasking machining centres are boosting drilling, thread forming, grinding, gear-cutting procedures required for the various stages of Shanghai Medical Instruments, which and broaching, in addition to turning and machining made traditional production slow supplies to hospitals around the globe. milling. and inef cient. The machines help to nish-machine up to Shanghai Medical Instruments has a Bumotec machines can produce complete six faces at high accuracy and in a single product range of more than 8,000 items, and components in a single clamping from bar set-up have also enabled the company to key products are knives, scissors and stock, nish machining up to six faces in expand pro tably into the manufacture of surgical clamps, as well as 400 different record time, in one case, up to 20 per cent minimally invasive instruments. types of micro instruments for anastomosis – quicker. Indeed, while the effectiveness of the the treatment of lymphatic vessels and limb The production of separate parts (on the machines at single set-up multi-operations reconstruction. same machine) for an orthopaedic instrument has brought great rewards in both prototyping Its portfolio also embraces instruments for assembly meets the rm’s stringent quality and manufacture, the company highlights its ENT surgery, orthopaedic implants and 300 standards. The two-part assembly is now latest Bumotec – the 5-axis s181 model with types of minimally invasive instruments, such produced with high accuracy, ready for 'front live tools' on a sub-spindle – as being as laparoscopic clamps (used in endoscopy assembly, and more cost-effectively by a able to boost productivity by 20 per cent on procedures), plus 400 dental instruments. Bumotec s191 rather than the former route some parts. The prototyping and production of certain of using a lathe, a mill then an electrical Capable of producing complex, multi- parts is a key area for the Starrag-supplied discharge machine to nish the parts to the
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | March 2021 45 MEDICAL SECTOR GLOBAL SOLUTIONS
methods, by the simultaneous use of the PB 840 high performance ventilators at their machine’s sub-spindle. purpose-built facility in Shannon, Ireland. Lee Scott, Starrag UK’s director for sales Due to the spread of Covid-19, demand for and applications, says the success can be ventilators jumped to unprecedented levels, mirrored by UK medical manufacturers: “The and Medtronic needed to produce 500 units UK medical manufacturing market is an a week, instead of 100, so Bolger had to important sector for Starrag and, underpinned ramp up production of individual parts. by our engineering applications knowledge, Sales manager Paul Collins explains ways we know that Bumotec users can ‘hit the of adapting to increase manufacturing ground running’ in terms of gaining capacity were quickly identi ed, including production ef ciencies.” bringing in 35 more staff and implementing new shift patterns to move to a 24/5 MAJOR LEAP operating model. He says the Radan CADCAM Brandauer engineer Alex Walton has Medical industry subcontractor Bolger software was seen a key enabler to manage worked on the manKIND visor Engineering is reaping the bene ts of what he describes as a “major leap”. investing in Hexagon Manufacturing “Our programmers typically take a 3D required standard. Intelligence ( www.is.gd/jAHW1p ) Radan model or DXF drawing and import it into The Bumotec s191H can achieve highly CADCAM software to help it meet a sharp Radan to tool the part for either the punch or accurate (to +/- 2.5 microns) machining increase in its manufacturing capability. laser machines, depending on material solutions within its X, Y and Z axes range of The company saw demand for intensive thickness and complexity of the pro le. They 410 mm, 200 mm and 400 mm, respectively, care ventilator components soar from 4,000 then nest and program the machine where courtesy of linear drives and high-level a week to over 18,000 and the increase in Radan gives the best sheet utilisation. This is thermal stability. In addition, its main spindle production looks like continuing into early hugely important, as more often than not, is complemented by a sub-spindle that can 2021. It uses Radan to program both of its material is the largest percentage of a job’s turn in both horizontal and vertical planes, for Trumpf ( www.is.gd/RM5AGq ) punching costs. So, optimising the cost here helps us multi-process routines, and tool magazine machines and Trumpf laser cutter, with the be market-competitive,” he says. options extend to up to 90 pockets on a material utilisation and optimisation crucial to Radan software allows the user to machine that has rapid traverse rates of 50 meeting signi cant demand. optimise manufacturing nests, it also enables m/min and a 30,000 (or 40,000) revs/min At the start of the coronavirus pandemic, components to be pro led within extremely spindle speed. Bolger was contacted by their long-standing tight tolerances of +/- 0.2 mm. The software Another example, concerns the production medical customer, Medtronic – a global ICU is also used to calculate the bend of an instrument for ENT surgery. This is ventilator manufacturer. They were already allowances, but the rm’s LVD press brakes produced on a Bumotec s181 in eight manufacturing components for Medtronic’s are programmed at the machine using the minutes, instead of 10 minutes by former Puritan Bennett PB 980 and Puritan Bennett proprietary software. ■
Recyclable visor to fi ght Covid-19 secures key certifi cation
A group of nine manufacturers, who developed a new recyclable He adds: “We can supply 1 to 5000 off a time, which means it visor to be used in the ght against Covid-19 in the UK have is very exible for smaller companies and charities. One of our secured CE certi cation for the product. largest purchases was from Make UK, who used the visors to The Manufacturing Assembly Network (MAN), which comprises protect their apprentices studying at its dedicated academy in eight subcontract specialists and an engineering design agency, Birmingham.” has supplied its 50,000th manKIND visor (pictured top left of the All nine MAN companies were involved in the project, with page) and is looking to double this gure over the next three Grove Design coming up with the working prototype and Barkley months. It is used by NHS hospitals, healthcare facilities, Plastics using its toolmaking and moulding expertise to create the charities and a host of commercial organisations. headband that is critical to the success of the product. The CE certi cation means the visor is approved and eligible to Crozier also explains: “The manKIND visor is part of a wider be part of the Medilink Midlands ‘Big Ask’ campaign to use West Brandauer approach to supplying crucial PPE, including Midlands rms to meet national PPE shortages. manufacturing 70 million nose clips per annum for medical face Rowan Crozier, CEO of Brandauer and lead on the MAN masks across the globe. project, says more than £30,000 was spent on the tooling, “We have even successfully secured Innovate UK funding to prototyping and manufacture and the rst 20,000 visors were come up with our own nose clip design and exible tooling that donated to local hospitals, care homes, voluntary organisations will support increasing PPE demand and reshoring activities that and to key workers. will generate revenue for UK manufacturing.”
46 March 2021 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets GOING FURTHER FOR MEDICAL INDUSTRIES
t CV5-500 Automation Solution
Automating high-mix, low-volume work has always been the ultimate challenge with complex 5-axis machining. Mazak’s new affordable CV5-500 is now available with an MA (Mill Assist) side loading robot to provide a seamless automation solution that will deliver more productivity and increased profits over a shorter investment payback time.
To discover more call +44 (0) 1905 755 755 or email [email protected]
www.mazakeu.co.uk/medical PRODUCTS & SERVICES TELEPHONE: Joe Opitz on 01322 221144 • FAX: 01322 221188 • EMAIL: [email protected]
X80657091_MYC_ROTATECH_MU.qxp 24/11/2015 17:14 Page 1
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To advertise here please call Joe Opitz on 01322 221144 Information Society Initiative launched; Centreline Machine Tool Company relocates from Hinckley to Nuneaton; RCS introduces a new punch press module for customised hole punching and notching machine; and benefi ts of the Internet
25years ago march1996
n the rst issue of March, our comment piece discusses the launch on choosing the right punch press tooling package. of the Information Society Initiative by the Department of Trade and We also have two turning features, reporting how higher than IIndustry (DTi) to promote the bene cial use and development of expected demand for a new product prompted radiation information and communications technologies’. We ask whether those thermometry Land Infrared to look for ways of combing machining charged with driving the society appreciate how long electronic data operations; no-frills, two-axis, turning-only CNC lathes still account has controlled the world of engineering manufacture, as since the for the majority of machines sold; and a feature on grinding, with dawn of numerical control, considerable expertise in the handling of the impending launch by Swiss-based Mägerle of a new space- electronic data has built up – and now controls the machines to the ef cient creep-feed grinding machine, specially designed for extend that robots, milling machines and CMMs can perform processing small parts. operations more quickly. We conclude, UK engineering businesses can In the second issue of March 1996, as the biennial MACH learn and capitalise from commercial areas of the society and urge machine tool show draws closer, the UK’s investment record is companies to join as membership would bring bene ts. under attack by the Labour Party, as it says manufacturing In news, multi-head and tooling manufacturer Centreline investment fell during the last quarter of 1995, hitting a level only Machine Tool Company relocates from Hinckley to a new factory seven per cent higher than during the depths of the recession. and headquarters in Nuneaton, coinciding with the start of However, we note to get an accurate picture you must separate company’s 25th anniversary; Toolroom Technology of Aylesbury is plant and equipment and recent gures show the UK’s appointed as UK reseller for model-maker desktop prototyping consumption of machine tools was up strongly. system from US-based Sanders Prototype; Seco Tools of Alcester In news, the three machines in Colchester’s Tornado CNC lathe now has pages on the Internet; subcontractor Laser Process range are re-christened ‘Storm’ for the North American market; places an order with Newall Aerospace for a laser cutting system; Velden Engineering UK purchases a Daewoo Puma 10HC CNC lathe and machine management specialist Wealdown Integrated Systems and Daewoo ACE V50 vertical machining centre from Mills develops a new machine to cut the time-consuming and costly Manufacturing Technology of Norwich; RCS (Tooling Systems) Ltd practice of transferring sawn off components to a nishing machine introduces a new punch press module for a customised hole by integrating sawing and machining operations into one unit. punching and notching machine; and there is a UK debut for the
NJ /stock.adobe.com In feature articles, our main lead is on punch presses, on rst Hitachi Seiki TF20 high speed compact turning centre to be why more attention is not paid to the choice of sold in the UK, to G.D Cocker & Son of Lytham St Annes. tooling, when the cost will be greater over the In feature articles, our technology focus is on the Internet, and lifetime of a punch press than the how the “communications system” can put businesses in touch machine itself. Eric Roberts, with the world; we look at the advances in CMM technology which technical director of tool are meeting the challenge of higher productivity rates and tighter manufacturer Wilson Tool component accuracy; nd out about Fidia’s new package that International, notes there optimises utilisation and operators’ skills; and have the rst of are signi cant productivity three MACH ’96 previews, looking at new developments the and economic bene ts machine tool industry will be offering visitors. ■
▼ ▼ ▼ The EU’s Veterinarian ▼ ▼ Mike Tyson TKOs Sri Lanka beat The Hubble Space Committee bans the Frank Bruno in Australia by Telescope export of British beef the 3rd round 7 wickets to photographs the due to “mad cow to gain the world win the 1996 50,000 swimmers raise £15m rst surface disease” (BSE) Sara- heavyweight Cricket World Cup for charity during photos of Pluto jevo mar 96 Elnur /stock.adobe.com title in Pakistan BT’s Swimathon
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The coatings for the highest performance
For more information: cutting.tools/en/dragonskin
50 Can’t trust your CAM? VERICUT is the only way to verify AND optimize your NC programs
Eliminate manual prove-outs Collision free machining Reduce cycle times Extend cutting tool life Improve part quality Maximize productivity
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www.cgtech.co.uk
Image courtesy of McDowell Machine Tools The new vibration- damped boring bar with an exchangeable head system for turning Modular combination options for high variability, flexibility and productivity
Find out more at: cuttingtools.ceratizit.com/gb/en/boring-bar
CERATIZIT is a high-technology engineering group specialised in cutting tools and hard material solutions. Tooling the Future www.ceratizit.com