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ISCAR is about to change metal cutting...

ISCAR believes it is set to revolutionise metal cutting once again with its latest product launch, the \\u2018LOGIQUICK\\u2019. This new brand signifies ISCAR\\u2019s new marketing theme and encompasses three keywords: \\u2018Logic\\u2019, \\u2018IQ\\u2019, and \\u2018Quick\\u2019. The previous campaigns by ISCAR have already highlighted the importance of intelligent cutting tools for advanced machining, providing logical solutions that meet the primary of modern production. With many of these tools becoming a market standard in numerous workshops worldwide, the addition of \\u2018Quick\\u2019 in the logo brings forth a sense of anticipation. What new challenges will the campaign products present? Is it simply a catchy brand name or a fundamental concept? Let\\u2019s explore the meaning of the logo and its implications.\\xa0

In the field of metal cutting, productivity is directly linked to the metal removal rates (MRR). To enhance machining rates, the metalworking industry strives for \\u2018fast metal removal\\u2019, which refers to processes that efficiently and swiftly remove material. These processes involve the utilisation of machines, strategies, techniques and cutting tools that enable faster and more effective machining. This reduces cutting time. However, in many cases, the primary obstacle to fully harnessing advanced, highly engineered machine tools and promising machining strategies lies in the cutting tool itself. The cutting tool often becomes the weakest link in the entire machining process, limiting potential gains in productivity and impeding the reduction of machining costs, and the growth of profitability.

ISCAR believes that the ultimate objective of a tool manufacturer is to supply cutting tools that ensure efficient metal removal. These tools should not only possess effective working characteristics to enable metal removal rates, but also exhibit qualities such as repeatability, versatility, user-friendliness, and a high utilisation factor. These attributes collectively represent the IQ of the tool, which is essential for leveraging the full potential of advanced machine-tool capabilities. This principle guides the development of cutting tools, harnessing the expertise of tool-design engineers, technologists, metallurgists, manufacturers, and all those involved in creating innovative tool solutions for intelligent machining in the metalworking industry.

ISCAR\\u2019s latest campaign unveils a range of groundbreaking cutting tools, including turning, parting, grooving, hole-making, and milling products. Let\\u2019s take a closer look at the LOGIQUICK portfolio to fully immerse ourselves in the campaign\\u2019s essence and delve into the details of these new developments.

Rotating tools

Steel construction beams play a crucial role in building structures and frameworks, requiring the drilling of numerous holes before assembly. However, the clamping mechanisms on machines often lack rigidity, posing a challenge for drilling. To address these limitations, it is essential for drilling tools to have an adaptive design that compensates for non-rigid conditions, and optimal drilling performance. Currently, finding an efficient drilling tool for beams is a top priority. ISCAR has developed a new solution (Fig. 1) based on the established SUMOCHAM concept of assembled tools with an exchangeable drilling head made from tungsten carbide. This solution incorporates three key elements - the cutting material, cutting geometry and body design.

The specially developed PVD-coated IC954 carbide grade offers exceptional resistance to deformation. The new IHP-BP exchangeable head features a dedicated-centring cutting edge, ensuring secure material penetration, while the sharp corners of the head effectively prevent the formation of burrs. Additionally, the reinforced drill body enhances dynamic rigidity. As a result, the new SUMOCHAM product provides an effective solution for drilling relatively thin beam sections under unstable conditions.\\xa0

Introducing another innovative rotating product, the modular SUMOCHAM drill head with MULTI-MASTER adaptation, which combines the strengths of two leading ISCAR product lines. This new drill head is designed to accommodate any of the SUMOCHAM exchangeable heads, providing the versatility of a modular tool assembly. It is specifically designed to be on a wide range of MULTI-MASTER shanks, allowing for easy customisation in terms of shape, overall length, and diameter. This not only reduces the tool inventory but also minimises the need for special drills. The combination of SUMOCHAM and MULTI-MASTER creates a promising synergy effect, offering tremendous potential.

Efficiently removing a large volume of material through milling is crucial in the production of critical duty-loaded parts, such as aircraft components made from titanium alloys. Extended flute indexable milling cutters, also known as \\u2018milling porcupines\\u2019 are highly effective for this type of machining, particularly when milling cavities, pockets and wide edges. The success of such tools depends on a combination of productivity, reliability, and cost-effectiveness. Introducing the QUICK-X-FLUTE (Fig.2), a new family of 90-degree extended flute shell mills with double-sided square inserts. These mills are designed with an optimised flute shape that strikes a balance between tool rigidity and effective chip flow, enabling high MRR with substantial radial engagement. The developed flute profile enhances vibration resistance, especially during workpiece entry and exit allowing for increased cutting data and improved productivity. The inner channels of the mill have replaceable nozzles and frontal outlets, facilitating direct high-pressure coolant supply (HPC) to the cutting zone. This improves cooling and lubrication, contributing to effective chip control. Additionally, the double-sided square insert offers 8 indexable cutting edges greatly increasing insert material utilisation.

Non-Rotating Tools

To achieve success in machining high-temperature superalloys (HTSA), the selection of the right cutting tool material is crucial. Introducing IC1017, a new tungsten carbide grade specifically designed for ISO-standardised inserts used in turning HTSA. This grade boasts a high-hardness submicron structure and is coated with PVD enabling higher cutting speeds for enhanced productivity.

The LOGIQ-6-TURN (Fig. 3) is a newly designed triangular insert that offers a cost-effective solution for semi-finish and finish turning with a focus on achieving high surface quality. This double-sided insert features a 55\\xb0 corner angle and positive rake cutting geometry, providing 6 indexable cutting edges. It presents a significant alternative to the standard ISO-type rhombic insert of DCMT type, which only offers 2 cutting edges. One key advantage is the ease with which LOGIQ-6-TURN inserts can be mounted on turning tools designed for triangular TNMG inserts.

Maximising profitability through the efficient use of raw materials during the parting process is crucial. ISCAR\\u2019s highly regarded DO-GRIP parting and grooving family has recently grown with the addition of three new sizes of double-sided inserts. This has been specifically designed for narrow parting operations (Fig. 4). These inserts are primarily targeted for Swiss-type lathes, enabling optimal material savings when parting small-diameter bars, tubes, and thin-walled workpieces.

The new tools are just a few examples of the various products introduced by ISCAR as part of the LOGIQUICK campaign. The numerous other product releases have significant interest and will soon be tested by manufacturers. With the increasing demand for quick metal removal, the need for advanced cutting tools continues to grow. This drives the development of tool designs and shapes the logic behind intelligent tool development.

Listed in: Business

ETG offers the right solution

When Chris Smedley of Malvern Engineering Ltd was made redundant, he walked out of his employment and 45 minutes later, he signed a contract for an industrial unit and started Malvern Engineering. This entrepreneurial spirit remains with the small business 15 years later with the company recently buying their first 4th-axis machining centre \\u2013\\xa0 a Quaser MV184 EV.

The journey for Malvern Engineering has seen the company manufacture everything from motorsport parts to military components and much more. It works with prestigious manufacturers in the automotive, aerospace, food and pharmaceutical sectors to the toolmaking industry \\u2013 like a typical subcontract manufacturer, Malvern Engineering will take on virtually anything that is thrown its way. This is why the company nestled under the shadow of the beautiful Malvern Hills has invested in a 4-axis Quaser machining centre from ETG.\\xa0

Recalling why the seven-employee manufacturer opted for the Quaser MV184 EV machine from ETG, Managing Director at Malvern Engineering, Mr Chris Smedley says: \\u201cWe are typically loyal to our suppliers, providing the quality and service is to the levels we require. However, we were on the cusp of winning a large contract that required a 4th axis machine for producing complex components \\u2013 and our vendor didn\\u2019t have the solution we needed. We investigated the market and found a couple of suppliers, but it was ETG and the Quaser that won our business.\\u201d

Delivered Autumn 2023, the new Quaser MV184 EV was purchased for several reasons, as Chris continues: \\u201cWe looked at a couple of machines, but when we visited the ETG technical centre and demonstration facility in Wellesbourne, we were flabbergasted by the quality, service and the set up of the company. The Quaser MV184 EV offers us greater flexibility than our existing machine tools and it enables us to reduce the number of required set-ups on complex parts. This is subsequently improving our quality, our throughput and creating greater efficiencies throughout the business.\\u201d

As a subcontract manufacturer with four 3-axis machining centres and two turning centres, the latest Quaser addition opens the door to new types of work that wouldn\\u2019t have previously been possible. Alluding to the benefits of the Quaser, Chris continues: \\u201cThe Quaser has a much more compact footprint than our existing machines, which is invaluable to a small business where space is at a premium. Like our existing machines, the Quaser was supplied with a Heidenhain CNC system which creates familiarity for our team to interchange between machines. With the latest generation of control, we are finding a lot of new features that will help create even greater efficiencies as and when we gain familiarity with the system.\\u201d

The Worcestershire manufacturer machines everything from 304 and 316 stainless steel, mild steel, aluminium, titanium and many more challenging materials in quantities that range from a one-off prototype to small production runs. Alluding to how the attributes of the compact Quaser machining centre are enhancing component quality, Chris continues: \\u201cAs a new machine, the Quaser is certainly more energy efficient whilst the kinematic movements of the machine and the 4th axis are also reducing cycle times and removing non-cutting time from component production. Added to this, the speed, efficiency and robust build quality are extending our tool life, improving our surface finishes and enabling us to essentially manufacture better quality parts with more aesthetically attractive surface finishes.\\u201d

Concluding on the level of service the company has received from ETG, Chris says: \\u201cThe machine has been a fantastic addition to our business and we haven\\u2019t had to lean on the ETG team that much so far. When we have needed their support, an engineer is available to resolve our queries almost immediately \\u2013 as a subcontract manufacturer that needs to get parts out of the door, that level of service will prove invaluable.\\u201d

Listed in: Business

Ceratizit - building a sustainable benchmark

New factories, a new logistics facility, a new sustainability initiative, a new management board, a new tech centre, company acquisitions and a host of new products planned for launch at the AMB show in September \\u2013 the recent Ceratizit press conference was a real eye-opener. The manufacturer has invested hundreds of millions of Euros in its infrastructure since MTD magazine last visited its European facilities in 2019 and the transformation has been truly remarkable. By Rhys Williams.

As one of the world\\u2019s leading cutting tool manufacturers, you would expect a level of re-investment to maintain a robust growth trajectory and industry-leading position, but what we found at Ceratizit last month was a seismic shift with new factories popping up at pace. Starting our whistle-stop tour across the German border in Reutte, the Austrian birthplace of the Plansee Group back in 1921, the rate of evolution was evident.

Kicking off the event with a presentation was Melissa Albeck; one of the three members of the \\u2018all-new\\u2019 executive board. Setting the tone for things to come, Melissa informed the press of the 14 company acquisitions since 2002, an overview of the new board structure and the new production site in Kreckelmoos on the outskirts of Reutte. It was evident the change was rapid and there was more to come\\u2026.There are also two new buildings in Kempten, Southern Germany, a new production site in Bulgaria and another in Poland, the introduction of additively manufactured carbide grades, the arrival of connACT \\u2013 the new sustainability strategy with a roadmap to carbon neutrality, the Product Carbon Footprint and the upGRADE range of recycled carbide grades that includes the CT-GS20Y grade that will be presented at AMB in September. As a journalist with massive overwhelm and too many exciting things to cover, there\\u2019s only one place to start \\u2013 at the beginning\\u2026

Following the presentation that whetted the appetite for what was to come, we toured the Reutte carbide manufacturing plant partially flattened by a catastrophic fire in 1996. From this disaster rose opportunity, a chance for Ceratizit to switch from acetone to water for its carbide manufacturing process \\u2013 and the group is the only manufacturer in the world that applies this environmentally beneficial process to its 75 different grades of carbide produced at this site. With more than 2,800 different types of carbide tools and 6,800 different insert designations manufactured at Reutte, the company produces more than 80,000 carbide inserts every day from this one production site. Even in this longstanding facility, investment has been significant in new tungsten processing silos, pressure sintering plants as well as CVD and PVD coating technology and furnaces with specialist chemical processes for breaking down used carbide for recycling.\\xa0

Much of the technology on show in Reutte was explained in more detail through afternoon presentations that were broken down into sustainability, innovation and additive manufacturing updates \\u2013 all supplemented by live demonstrations.\\xa0

Leading the Sustainability Drive

Sustainability has become interwoven into the fabric of manufacturing and a push towards carbon neutrality is a long-term aim for most companies. The foresight Ceratizit applies to its growth strategy also incorporates its green credentials. The company has acquired Tikomet, GTP and Stadler in recent years \\u2013 companies located in the US and Europe that recycle tungsten carbide. These businesses are foundation blocks in the company\\u2019s drive to create a circular economy model for carbide. Subsidiaries across both continents are collecting cutting tools from customers with incentivised discounting that is claimed to see upwards of 87% of Ceratizit\\u2019s carbide now entering the recycling chain. Ceratizit is continually reducing its mining of raw materials. The aim is to increase its share of raw materials remaining in the carbide production chain to over 95% by 2030 \\u2013 a figure based on scrap recycling of sintered products. \\xa0

The recycling model is proving a huge success with the company already ahead of its target to reduce CO2 emissions from the 2020 baseline figure of 191,000 tonnes by 35% by 2025. With targets to reduce this by 60% by 2030 and 90% by 2040, Ceratizit isn\\u2019t only leading the way with this drive, it is setting new standards. This was presented with the company\\u2019s new \\u2018Product Carbon Footprint\\u2019 (PCF) \\u2013 the first VDMA-verified standard for calculating and classifying the carbon footprint of carbide products. The new classification will provide customers with the carbon footprint journey and impact of their cutting tools, something that Ceratizit is tirelessly calculating for all its 64,000+ standard product lines. This information for all standard products is expected to be completed and available for presentation at the AMB show in September. Furthermore, as the company continues its sustainability drive, the PCF of each product will constantly be reclassified to demonstrate the ever-diminishing impact of products on the environment.\\xa0

Pivotal to hitting its aggressive targets in the sustainability journey is a strategy to target every aspect of the business. This includes a switch to green energy, the introduction of green hydrogen, recycled packaging with 60% less CO2, solar parks introduced in India and Luxembourg, the 3D printing of carbide grades and much more.

Investment Drive

With fascinating insights into the transformation at the Reutte plant and a glimpse at everything from new products, sustainability, additive manufacturing and R&D our afternoon trip consisted of a visit to the new Kreckelmoos facility in Tyrol on the outskirts of Reutte. This put the scale of the investment strategy into perspective.

When you see the building from the outside, you might think it is a new hotel at first glance. A beautifully designed wooden facade, large windows reflecting the surrounding mountain landscape and lots of greenery. But what at first appears to be a wellness resort is a production facility built for the future.

Ceratizit started construction on the site in 2019 and this was completed just over a year ago. With a gross floor area of 45,000sq/m and an overall manufacturing site of 370,000m³, the new facility won the German Design Award 2024 for \\u2018Excellent Architecture\\u2019, an award that that recognises innovative and sustainable design developments. With its innovative energy concept, it sets an important foundation for a more sustainable future \\u2013 in line with Ceratizit\\u2019s corporate sustainability strategy. Comprising production halls, storage and logistics areas, offices and social rooms for over 300 employees, the site manufactures carbide tools, coating materials for displays, electrodes for glass melting and components for the semiconductor industry and medical technology.\\xa0

The story of the new building began more than six years ago under the premise of growing further at the location in Reutte. But where? After an intensive search, a suitable building site was found on a former landfill site. The Breitenwang neighbourhood of Kreckelmoos is only one kilometre away from the main site in Reutte. The planning and concept phase was followed by the tendering process and finally the start of construction in March 2019. The moving-in process began in January 2023 and is expected to continue until the second half of 2024. This was evident with large areas of the facility still awaiting production equipment installation during the tour.

Winning the German Design Award 2024, the site has an energy-efficient concept brought to reality with the use of thermal groundwater, heat pumps and photovoltaic systems. The 15,000sq/m extensively greened roof of the production hall also contributes to low energy consumption. This modern three-story building is also visually impressive. The visible timber supporting structure made of local spruce is particularly eye-catching. Using this naturally renewable building material has enabled low-emission construction, which perfectly fits in with the sustainability strategy.

Supply Chain

After a visit to a brand-new manufacturing facility, you\\u2019d typically think that you have seen the highlight of the trip, but in true Ceratizit fashion, the company raised the bar by organising a visit to the new logistics, distribution and supply chain centre in Kempten. Across the border in Southern Germany, MTD magazine visited the Kempten distribution centre in 2019 where plans were afoot for a new facility. Five years later, MTD magazine returned to see the new state-of-the-art logistics centre that was opened on Valentines Day 2021.\\xa0

In the aftermath of Brexit, many UK manufacturers had valid concerns over supply chain continuity \\u2013 an issue that never really surfaced for businesses working with Ceratizit. Credit to its slick supply-chain strategy and huge investment in the new site, over 65% of Ceratizit\\u2019s European manufacturing output is delivered to more than 74 countries via the Kempten facility with 99% next-day delivery. Fundamentally quashing supply chain concerns.

Whilst the previous site was a sight to behold and akin to an Amazon warehouse, the new facility takes automation to a new plateau. The new building has a footprint of around 17,000sq/m, which is similar to the previous site. However, with 99% automation, the new facility currently ships more products with less staff than the previous site \\u2013 despite running at just 60% capacity. In numbers, the new site ships more than 24,000kg of products every day. This equates to upward of 90,000 product parcels being shipped to more than 4,000 customers with an average order value of over \\u20ac500.\\xa0

The level of automation at the new facility now sees 125 staff pick over 400 product parcels per hour compared to the previous 60 picks per hour, demonstrating the efficiency of the new site. With over 3500 boxes leaving the facility daily, it has a shuttle system that collects, stores and sorts more than 700 parcels that are delivered to the site daily from production sites around Europe. Undertaking this mammoth task, products are automatically added to and then collected from a 31-level holding area - each level is 60m in length with room for significant expansion to add to its current 400,000 storage spaces. From the colossal shuttle system, products are automatically delivered to specific picking locations where the staff operate under completely \\u2018fail-safe\\u2019 parameters and where quality checks, as well as packaging, labelling and shipping tasks are undertaken.

Dovetailing into this facility are standard and special products from the unfathomably diverse product portfolio and brands within the group as well as carbide products manufactured by Ceratizit for many of its competitors across Europe. Upstream from the slick logistics centre, Ceratizit has continually enhanced its customer-centric position with advanced technology that identifies customer behaviour and purchasing patterns. This ranges from the 24/7 tool supply via vending machines to complete e-commerce solutions that connect directly to customer ERP systems to expedite the procurement process \\u2013 a behind-the-scenes investment that now sees special products manufactured and delivered in less than 3 weeks.\\xa0

In the next issue of MTD magazine, we\\u2019ll continue our insightful look behind the scenes of Ceratizit and its activities in Europe. We will also take a closer look at some of the exciting new product lines that will be arriving in the autumn. There are a multitude of product launches planned for the AMB show in September, so make sure you pick up our July issue to find out more.

Listed in: Business

Bumotec solves medical production puzzle for Dawnlough Precision

Dawnlough Precision is a subcontract manufacturing business that has travelled a relentless journey of growth since it started manufacturing tooling for the aerospace and medical industries back at the start of the millennium. The ascension to success has arrived through an aggressive growth strategy and investment in high-end machine tools. Part of this high-level investment journey has included the arrival of two Bumotec 191neo turn/mill centres from Starrag. By Rhys Williams

Initially founded in 1987, the turn of the millennium has seen the Galway manufacturer gain accreditation to ISO: 9001, ISO: 13485 and AS: 9100D, establish a design department and increase its manufacturing facility to 50,000sq/ft. Underpinning this growth is the adoption of advanced production tools such as FMEA, PPAP and SPC.

To maintain its growth trajectory, Dawnlough has invested in the most flexible, capable and productive machine tools \\u2013 and this is why it has recently taken delivery of two Bumotec 191neo machines. The world-class production facility on the West Ireland coast has more than 54 CNC machine tools that provide premium manufacturing solutions. Recently acquired by the Acrotec Group, the 110-employee business is still run by longstanding Managing Director and previous owner Brian McKeon.\\xa0

Looking at the path the business is taking, Keith Kennedy, Aerospace Production Manager at Dawnlough says: \\u201cWe manufacture high precision components for the Aerospace and Robotic Assisted Surgical Industries as well as tooling and production aids for the medical device sector. When I started in 2006, tooling was the main business focus, but as the aerospace and medical device industries have expanded locally this presented many opportunities. Our aerospace work started with seating components for Rockwell Collins, which led us to 5-axis machining. We then progressed to flight-critical components for the likes of Spirit Aero Systems and Pratt & Whitney. Similarly, we progressed from manufacturing medical tooling and instruments to producing complete assemblies.\\u201d

Discussing the expansion in the medical industry, Keith continues: \\u201cOur core business has predominantly focused on vascular work and from this, we have expanded our offering. We now produce an array of components for our RAS customers as well as consumable instruments.

The First Bumotec on the Emerald Isle

It is here that the search for a suitable machine led Dawnlough to purchase a Bumotec 191neo FTL-R in June 2022. Discussing the acquisition, Keith recalls: \\u201cWe had several components we initially targeted for this type of machine.\\u201d\\xa0

\\u201cWe needed a machine with very high levels of accuracy, short cycle times and incredible efficiency because it\\u2019s a very competitive market. We visited many companies, reviewing high-accuracy machines, but it\\u2019s only as you look closer and purchase one of these machines for this type of work - you really see the \\u2018value-add\\u2019 they bring. We were looking for repeatability, flexibility, high spindle speeds, the ability to machine hard material and 2-3\\xb5m precision on production runs. We had very specific requirements and we were not sure if it was going to be achievable.\\u201d

\\u201cSome of our initial trial parts were 46HRc and we are using tools from 0.1 to 0.5mm. We needed repeatability of 2 to 3\\xb5m, but we needed to hold that overnight. Some of the functions of the Bumotec machine such as the software for monitoring the machine, the cutting load, the contact cutting time and the large 90 tool ATC in the machine are incredible.\\u201d

\\u201cIt was a huge investment and an unknown risk, but the Bumotec ticked all of our boxes. The big thing about Bumotec was the flexibility. It offered everything we wanted. It\\u2019s an exceptional machine with accuracy that takes our business to a different level.\\u201d\\xa0

As well as machining 46HRc parts, there was also a need for specific RAS parts that were a key driver to the first Bumotec installation, Keith says: \\u201cWe were machining these parts in batches of 200-off up to six times a year and there are 6 different parts in the family with a projected ramp-up of 200-300% a year. So, we wouldn\\u2019t have been able to support the customer with our existing method. There was also a fallout due to accuracy, as we couldn\\u2019t 100% meet the GDT accuracy.\\u201d

\\u201cWe needed to put a bar diameter in the machine up to 1.5 inches whilst also running high precision production runs of small instrumentation parts. The Bumotec also had the sub-spindle and a robotic unit which was important, as we need traceability for every part we make. We took demonstration parts to Bumotec in Switzerland in April 2022 and we received the machine in June.

Success Brings Machine Number 2\\u2026

Following the success of the Bumotec 191neo with FTL-R configuration, the Galway company then added a second Bumotec 191neo in March 2023. Supplied with an FTL-PRM configuration, the second Bumotec 191neo was introduced with complete automation and a 20-position pallet station for lights-out production. As Keith continues: \\u201cWhat they offered us with the second machine was a complete turnkey solution for our instrumentation components. We had given them a target for extreme levels of precision and production volume with the flexibility to produce families of parts.\\u201d

\\u201cWe needed to machine materials from 46 to 52HRc such as 17-4 and 420 stainless steel as well as titanium. The instrument parts for use in invasive robotic surgery include tools like grippers, cutting instruments and scissors. We are producing the parts in medium to high volume runs across two different parts in various quantities per month.\\u201d

Some of the parts had very long cycle times on the 5-axis machines and this needed to be reduced to below 30 minutes with 48HRc material. Not only was the cycle time a challenge, but Dawnlough had to attain precision levels in a production environment with the flexibility to produce upwards of 30 different components. Initially machining 20 to 50 parts a month, the schedule was set to rise rapidly to 200 parts per month before reaching production volumes \\u2013 numbers not possible on a 5-axis machining centre.\\xa0

\\u201cWith the second machine, we knew exactly what Bumotec could offer, so we worked with them remotely. What Bumotec offer is exceptional and way beyond anything we had anticipated. With the original Bumotec 191neo FTL-R, we had the sub-spindle, but with the next set of parts we needed the Bumotec 191neo FTL-PRM. With this machine, we had the option of the vice, a 3m bar feed and also a robot loader. We needed the robot loader for traceability. It also expanded the capacity of the machine where we could go from 50mm barfed stock to 80mm billet loading.\\u201d

\\u201cThe sub-spindle option we had on the FTL-R wasn\\u2019t feasible for the parts we needed, whereas the FTL-PRM gave us two vices. Without the vices, we would have needed to undertake secondary machining, so to be able to pick up the component in the vice and conduct the second operation in a single cycle was key to finishing the parts.\\u201d

Contributing to the conversation, Dawnlough\\u2019s General Manager, Mr Eddie McHugh adds: \\u201cWe were machining parts on our 5-axis machining centres and we needed to increase output by 400%. We were machining around 400 parts a month on two different products with a cycle time of 45 minutes. This was tying up two machines and one man permanently every month. On second and third shifts with fewer staff, we had concerns about machine tolerance drift, so output was reduced and it also made inspection labour intensive.\\u201d\\xa0

Looking at additional savings with the arrival of the Bumotec 191neo FTL-PRM, Eddie adds: \\u201cThere is a labour saving with one man running two machines around the clock. Additionally, with the pallet loader, the parts are loaded into the machine and back to the pallet loader in a specific order which made huge savings on inspection. We have also made considerable savings on tool costs and changeovers and this is a credit to the 40,000rpm spindle.\\u201d

With machine tools from 10 different manufacturers, Dawnlough has one machine alongside the two Bumotec 191neo that is commonly used in the medical industry. Comparing this machine to the Bumotec, Keith continues: \\u201cIn comparison, the Bumotec has increased capacity, it has a larger tool library, higher spindle speeds, a larger diameter bar capacity and a lot of other features that just offers so much more flexibility. It\\u2019s not only a better and more flexible option, it\\u2019s a more robust machine.\\u201d

The Future

Looking to the future, Dawnlough has plans for more Bumotec machines and continued expansion, which will certainly continue with the ambition of the Acrotec Group. \\u201cThe machines are extremely flexible and this means we can just change the programmes over, the jaws and collets and it is ready to go in less than 2 hours. For our high-precision mid to high volumes with a high mix of complexity \\u2013 the Bumotec is the perfect machine for our business.\\u201d

Service

Dawnlough is well positioned to serve its customers \\u2013 but machine tool suppliers have not always served Dawnlough with a level of customer support that a leading

manufacturer would expect. Referring to the service and support from Bumotec, Keith concludes: \\u201cThe service is exceptional. There is absolutely no comparison to some of our other machine suppliers. Starrag is a brand with a limited footprint in Ireland and I believe our Bumotec was their first machine in Ireland. Despite other brands having a larger footprint in the area, the Bumotec support is second to none.\\u201d\\xa0

Eddie concurs by adding: \\u201cThe service from Bumotec is probably the best we have had. If you need engineering support they are there straightaway, whether it\\u2019s engineering support, post-processors, technical queries or anything else. The support has been fantastic.\\u201d

Listed in: Business

ARCH partnership with Hexagon is cruising

Hexagon\\u2019s Manufacturing Intelligence division and\\u202fARCH Motorcycle, a manufacturer of high-performance bespoke\\u202fmotorcycles, have partnered\\u202fto support the quality control demands of engineering and producing unique riding experiences for ARCH customers.

By combining artistry and engineering with precision technologies, ARCH maximises the performance potential of its motorcycles while keeping innovation at the forefront of design. The partnership is geared to help ARCH expand its commitment to producing bespoke\\u202fmotorcycles by\\u202ffully digitising quality processes throughout engineering and manufacturing with state-of-the-art measurement technologies.\\u202f

ARCH Motorcycle was founded by Keanu Reeves and Gard Hollinger in 2011 to challenge the perception of what an American motorcycle could be. Anything that compromises the ride, aesthetics, stance, or function is treated as an opportunity to innovate and improve the design. ARCH owners seek more than just a machine. They are passionate individuals in search of a completely immersive riding experience. Every ARCH motorcycle is built from an obsession for innovative design, engineering excellence and dedication to the rider \\u2013 and that is why the company is working closely with Hexagon.

3D scanning technologies to be implemented by ARCH Motorcycle include Hexagon\\u2019s equipment and software for reverse engineering, which will enable ARCH\\u202fto retain classic design elements for application to products in development. The technology will also help ARCH Motorcycle\\u202fcreate tailored\\u202fergonomic motorcycle designs that incorporate individual customer specifications for shocks, seats, handlebars, foot controls, and overall fit.\\xa0

\\u201cAt ARCH, we strive for\\u202fprecision machining and\\u202fattention to detail for\\u202fcrafted\\u202fproduction motorcycles.\\u202fOur goal is to integrate Hexagon\\u2019s latest metrology technologies throughout our manufacturing and quality control processes to achieve\\u202fa meticulous finish and\\u202funcompromising quality for every ARCH\\u202fmotorcycle. The ability to quickly digitise parts will also streamline\\u202four 3D digital workflows for CAD and the production of bespoke parts that enhance a rider\\u2019s experience and comfort.\\u201d\\xa0

\\xa0The ability to quickly digitise part dimensions and surface finishes for comparison to CAD models\\u202fand quality standards will enable ARCH\\u202fto improve both throughput and quality control easily and with confidence in their data. It also allows the company to keep an accurate digital 3D record of each customer\\u2019s motorcycle to support future customer service.\\xa0

Hexagon devices to be used by the ARCH manufacturing team\\u202finclude the easy-to-use\\u202fportable Absolute Arm measurement technology with a state-of-the-art\\u202fAS1 laser line scanner) that enables even inexperienced users to capture measurements directly into associated software. The 3D laser scanner provides a guided workflow that helps users to visualise 3D models and it guides them through successful coverage of critical features and surface measurements. Paired with tightly integrated measurement software, the laser scanner also makes it easy to scan large components and reverse engineer parts.\\xa0

The Absolute Scanner AS1 can collect up to 1.2 million data points per second at a line rate of 300 Hertz \\u2013 even at maximum data quality and scan line width settings. This allows for surface and feature measurement without any need to slow down to ensure data quality. The AS1 is also fully high-speed automation compatible, making new worlds of high-productivity measurement possible. With the AS1, programmed robotic scan paths no longer need to be limited by the data collection speed of the scanner \\u2013 the AS1 has been designed to keep up with the world of smart manufacturing.

\\u201cQuality control represents different challenges for every manufacturer, but it can be especially challenging for those who produce highly customised products,\\u201d\\u202fsaid Brian Winters, Product Manager for Absolute Arms at Hexagon.\\u202f\\u201cWe\\u2019re excited to partner with ARCH Motorcycle to provide flexible tools that make it easy to digitise measurements as components are made and assembled. This immediate access to accurate 3D measurement data is intended to help produce the one-of-a-kind experiences and production motorcycle quality that customers want.\\u201d

Listed in: Business

STUDER forms success for TEMSA

The Spanish TEMSA Metallurgical Group is one of the world\\u2019s leading manufacturers of special tools for cold forming. The company also uses cylindrical grinding machines from STUDER in its production facility in Barcelona.

Alfonso Vivar walks through a large hall that radiates a sense of order, despite its multitude of machinery, workstations with monitors, and focused employees. Everything has its place, every work step is carefully planned, and at its heart is a yellow robot arm working away methodically in an 8,000sq/m plant to the west of Barcelona, Spain. Production Manager Alfonso Vivar knows every corner of the plant. His shirt bears the bright red logo of his employer, TEMSA Metallurgical Group, a leading global specialist in the production of high-precision tools for cold forming and an expert in powder metallurgy, sintering and fine cutting.

With cold forming, metal below the recrystallisation temperature is forced into a specific shape using high compressive and tensile forces. Compared to metal-cutting operations, this allows for shorter processing times per workpiece, thereby reducing costs in series production. Cold forming also allows for high strength, complex geometries, and excellent surface properties of components for high-tech industries such as aerospace and automotive.\\xa0

\\u201cOur team can manufacture special tools in a tolerance range of just a micron,\\u201d explains Vivar, proudly. TEMSA\\u2019s site in Barcelona has around one hundred employees, all working to manufacture tools to exacting customer requirements. \\u201cOur expertise also helps us to accomplish short lead times. But that\\u2019s only because we use the very best machinery.\\u201d\\xa0

Confidence in the Technology

\\u201cWe acquired a new STUDER S100 earlier this year, together with a favoritCNC.\\u201d Vivar points to the CNC universal internal cylindrical grinding machine, painted white with blue accents. This colour combination is typical of STUDER\\u2019s cylindrical grinding machines and is a familiar sight at the TEMSA plant. The company operates several STUDER machines for grinding tasks, including the S131, a new generation CNC universal machine for internal cylindrical grinding. \\u201cWe have confidence in the technology, and value the positive relationship we have with the manufacturer,\\u201d explains Vivar of the decision to invest.

As an example, the S100 is a great all-rounder offering maximum precision thanks to its numerous options for internal, face, and external grinding. The machine facilitates the production of a wide range of workpieces up to 550mm in length. The favoritCNC is a CNC universal cylindrical grinding machine for individual and batch production of medium-sized workpieces with a length of up to 680mm. Both machines have an exceptional price-performance ratio, while at the same time offering premium technology, such as the machine bed of solid mineral cast Granitan\\xae and optimal hardware-software interplay for ease of operation. The S131 for internal cylindrical grinding with a patented StuderGuide\\xae guide system, turret wheel head with up to four grinding spindles, and an additional C-axis is ideal for high-precision manufacture of flanged parts and smaller workpieces in a wide range of applications.

In addition to the quality level of the machinery, Vivar cites another important reason for opting for STUDER: \\u201cThe customer service is outstanding, and we have several contact persons who can speak Spanish,\\u201d he explains. This helps to ensure easy and direct communication. He also values what STUDER has to offer in terms of preventive maintenance. This includes regular and routine inspections of the machinery by STUDER\\u2019s technical personnel, designed to minimise the risk of production failures and improve their operational durability.

Riccardo Delai, Sales Manager for Latin Europe at STUDER visits the plant in Barcelona at regular intervals and is often on the phone with TEMSA employees. \\u201cPersonal contact is extremely important as it helps me to know what is working well and what needs attention. We are delighted with the international success of TEMSA as a fully Spanish company, and it demonstrates what can be achieved with our machinery,\\u201d emphasises Delai.

Investing in the Future Safeguards Success

TEMSA\\u2019s success story goes back more than 30 years when the fledgling company produced high-precision tools from tungsten carbide and steel. Through consistent investment, the Spanish company has quickly been able to establish an excellent reputation around the world. Today, the company is a world leader in special tools for cold-forming processes. \\u201cI am extremely proud of our team. We have many second-generation employees working with us, and at Christmas, we always have a meal together with the first generation,\\u201d explains Vivar, a TEMSA veteran of 25 years.\\xa0

This appreciation for tradition is paired with foresight for the future, and TEMSA was an early adopter of automation to make production more efficient. One such example is the yellow, 360-degree operating robot arm here in the plant, which automatically sorts numerous tools and allocates them to the machine according to requirements and processing cycles. \\u201cWe want to move automation up a level in the future, which is a real challenge,\\u201d explains Vivar. This is another area in which STUDER is a valuable partner, having ample experience in customised and standardised automation solutions. As an example, the S100 can be equipped with a loader interface and automatic sliding door and thus integrated into an automated production line. The S131 also has a standardised interface for a loader and peripheral equipment.

Listed in: Business

Renishaw proves effective for retrofit specialist

Effective CNC Solutions Ltd is a machine tool retrofit specialist based in Crewe, UK. A few years ago, its founding director Gary Pearson had a vision to develop a machine tool that would perform additive manufacturing (AM) and conventional subtractive manufacturing as a single process on the same machine.

Although AM can produce many components in just one process, some functional features or surfaces may require further post-processing, such as CNC machining or finishing operations, to achieve the full design specification in the final part. An ongoing goal for additive manufacturing is to make any such post-processing steps as quick and straightforward as possible.

To help Effective CNC design and build the new machine, global engineering technologies company Renishaw provided support with its technical teams specialising in optical position encoders, tool setters and machine tool probes.

Effective CNC has selected a range of Renishaw products, including the FORTiS enclosed linear encoder series, the RMP60 probe and a custom tool setting system to build a machine prototype that integrates the additive manufacturing and post-processing of some metal parts.

In the post-processing of additively manufactured parts, the propagation of geometric errors can impact the machined surface accuracy of the final product. The finishing of additive parts often involves several machine transfers which can introduce workpiece position and angular errors that need on-machine probing systems for compensation. There is also a cost and productivity penalty associated with operating multiple machines.\\xa0

Hybrid machines that combine both conventional machine tools with an additive manufacturing head are a relatively new concept that can improve the economics of AM for certain applications.

The team at Effective CNC has designed and built an \\u2018all-in-one\\u2019 machine that can perform both additive and subtractive machining operations in tandem. This, they claim, will help to revolutionise the economics of many large, precision AM metal builds.\\xa0

\\u201cWe created a fixed rigid position for a spindle, a wire deposition additive manufacturing head and, in this machine, a turning turret,\\u201d said Gary Pearson, Director of Effective CNC when explaining the unique features of the new machine. \\u201cWe can move the workpiece around in all five axes and take it between the various stations to add and subtract and add and subtract, without having to move the actual tooling around.

\\u201cWe took a wire deposition additive manufacturing system, which is a very clever MIG welder, and put it onto the machine in a fixed position. This allows us to add the base material onto a clean build plate and then machine it back without having to take the product off the machine. Because we can add material in five axes on the machine, we can build very complex shapes and machine them back to very accurate tolerances without having to take them off the machine at all,\\u201d continued Pearson.\\xa0

Another innovative feature of this machine is that it incorporates three cutting processes - milling, turning and grinding - in addition to additive processing, enabling an additively manufactured part to be built and finished on a single machine.

The basic machine design comprises a holder for a workpiece, a spindle for milling and grinding the workpiece, and a rotatable tool turret. A trunnion table supports the build plate and provides the 4th and 5th axes of the machine. For enhanced machine tool safety, components such as the controller and position encoders have been chosen that are certified to Functional Safety (FS) standards.\\xa0

Effective CNC chose FORTiS-S\\u2122 FS enclosed encoders for the X, Y and Z-axes including a specially-built long FORTiS encoder (X-axis) with a scale length of over 3m. For the trunnion table (A-axis), Renishaw\\u2019s RESOLUTE\\u2122 FS absolute optical position encoder with a RESA ring scale was selected for rotary position feedback.

The FORTiS encoder series is a next-generation linear enclosed absolute position encoder for use in harsh environments such as machine tools. An advantage of the FORTiS enclosed encoder is the quick installation and set-up which is substantially faster than conventional systems, even in restricted locations.

Mr Pearson reveals how Renishaw products were integrated into every machine process: \\u201cWe purchased two FORTiS systems they are plug-and-play and very easy to install and set up,\\u201d explained Pearson when revealing how Renishaw products were integrated into every machine process. \\u201cRenishaw also supplied us with an RMP60 probe system for measuring the workpiece, which works very well. They also developed for us a hybrid system that combines the NC4+ Blue laser tool setter for the milling tools and an RP3 tool setting probe for the turning tools.\\u201d

\\u201cRenishaw\\u2019s technical support team visited us to look at what we were doing on the machine, where we needed to install it [the tool setting system] and what we needed to achieve and then drew us some CAD models. We were able to drop those into our CAD model of the machine and see how they integrated. They provided us with everything we needed,\\u201d continued Pearson.

The innovative approach taken by Effective CNC also extends beyond the machine format and tooling. A novel tool-changing robot has also been developed. \\u201cWe decided that rather than building a cartesian robot with a complicated tool change structure, we chose an off-the-shelf solution in a collaborative robot,\\u201d explained Pearson.\\xa0

The cobot chosen is from Universal Robots and has joints fitted with AksIM\\u2122 series magnetic rotary encoders from Renishaw\\u2019s associate company, RLS. When paired with a pallet changer, the cobot enables the machine to run \\u2018lights out\\u2019 with no operator intervention.

A close collaborative relationship with Effective CNC has enabled Renishaw to bring its 50 years of machine tool industry expertise to bear in helping to choose the best and latest technologies for this machine concept.

\\u201cFrom an additive point of view, we can create components that are larger than the machine table because we can manufacture in five axes,\\u201d said Pearson. We can build a cylinder and rotate the components around and build on the side of that cylinder any shape you like. And that gives us the capability to manufacture a large component that even overhangs the build plate.\\u201d

The machine is a versatile system that successfully combines milling, turning and grinding with an additive manufacturing device, which it is claimed will substantially increase end-to-end process productivity and enable the AM manufacturing of challenging metal parts such as outsized pipe bends and fittings for the oil and gas industry.

\\u201cWe feel we have a new and strong product for the high-tech industries, and we\\u2019re looking forward to the future with great enthusiasm,\\u201d concluded Pearson.

Listed in: Business

Raising the Bar

Specifying materials and the right suppliers for projects can be fraught with challenges, especially when searching for high-performance stainless and nickel alloys. MTD magazine gets an insight into material selection from Langley Alloys to provide our readers with a greater overview.\\xa0

Founded in 1938, Langley Alloys was created to develop high-performance alloys for naval and aerospace applications and its history includes the patent for the very first commercial super duplex stainless steel, Ferralium 255 and the invention of the highest-strength copper-nickel alloy Hiduron. This is now widely used in modern subsea applications.

Rising from the special copper alloys division of High Duty Alloys and developed into a fully integrated metal production company on a site at Langley in West London, it grew steadily throughout World War II. This acceleration was accredited to several successful alloy developments, including the high-strength Naval alloy Hidurax Special and the copper-bearing alloy, Hidurel\\xae 5, which was a major engine bearing on the Spitfire aircraft. Elements of its proud history are still visible today, as Langley Alloys continues to supply a family of unique products for demanding applications.

Continued investment in in-house inspection, testing and machining capabilities allows Langley Alloys to be a \\u2018one-stop\\u2019 supplier of choice, saving manufacturers considerable cost, time and effort. As Rodney Rice from Langley Alloys tells MTDCNC: \\u201cWe have three metallurgists within the business, so we can easily translate the difficult parts of customers\\u2019 requirements and specifications into a simple order. Dealing with the uncertainties of the material supply chain can be complicated. For us, it\\u2019s about having a plan and being flexible. Looking at customer demand and their requirements, we are looking at metal pricing and we are trying to assimilate all of that information with science and a little bit of gut feeling to decide what stock we should be carrying, when and in what quantities.\\u201d

\\u201cEvery piece of stock for sale is catalogued and captured on our inventory management system. So we know exactly what we\\u2019ve got, where it is and if it\\u2019s available with all the paperwork that tracks its traceability. This is fundamentally important to all of our customers. When we supply to CNC machinists, they will take cut pieces, full-length random bars or pieces cut to a certain length to fit a bar feed. It\\u2019s all about presenting the material in the best possible way. A standard bar will have a plus tolerance anyway but depending on the application, we can supply ground, straightened or polished material for more critical tolerance work.\\u201d

\\u201cOur business is best known for duplex and super duplex steels, but we also offer a range of nickel alloys and copper nickel alloys as well. These are all high-strength, highly corrosion-resistant and high-performance. The one thing these materials have in common is they are suitable for wet corrosive aggressive environments. There will be a solution for pretty much any application.\\u201d

\\u201cWhen it comes to traceability, it is absolutely fundamental for our customers\\u2019 applications, so we take a great deal of time and effort to make sure we can maintain the traceability of the product. We colour code, hard stamp and label materials to ensure that the location of the material is tightly controlled at all times. As the business continues to grow, we\\u2019ll continue to explore export markets as this has been extremely successful for our business. We may add one or two more products to the portfolio, but on a technical level, we are excited to look at some of these newer markets and applications. Desalination is becoming more mainstream, hydrogen economy is going to pause more challenges in terms of metal selection the medical industry is a growing market segment,\\u201d concludes Rodney.

Listed in: Business

Out with the old...

A leading mechanical and fluid power transmission specialist has traded in a twelve-year-old Doosan vertical turning lathe for a new DN Solutions model to increase its in-house machining capacity and capabilities. Mills CNC, the distributor of DN Solutions\\u2019 machines has recently supplied Surrey-based jbj Techniques Ltd with a new, FANUC-controlled vertical turning lathe.

Celebrating its 50th year in business, jbj Techniques is a family-owned business that currently employs 25 staff in Redhill.

As for the DN Solutions\\u2019 24\\u201d chuck Puma V8300M, it was installed at the company\\u2019s 7200sq/ft facility in January 2024 and has replaced an older Doosan VT750M vertical lathe. The new machine, with its compact footprint and box guideway construction, is equipped with a powerful, high-torque 30kW 2000rpm 3153Nm spindle making it ideal for machining hard and difficult-to-machine materials.

The V8300M also has driven tooling capabilities with an 18.5kW 4,000rpm spindle that increases flexibility, enabling complex parts to be machined in one set-up. Furthermore, the integration of a 12-tool position side-mounted ATC in addition to its existing 12-tool station turret, increases productivity by reducing downtime caused by tool changes.

The Works Director at jbj Techniques, Mr Ben Stubberfield says: \\u201cOur new V8300M is has significantly improved our in-house vertical turning capacity and capabilities. The new machine has replaced a previously-acquired VT750M vertical lathe which, although being a good machine that had served us well over the last 12 years, didn\\u2019t have a big enough turning diameter to machine some of our larger components. This resulted in us having to use an older, and much slower, lathe for these applications which, on occasion, affected our process efficiencies.\\u201d

With its reputation built on quality, service and speed of response, jbj Techniques decided to replace the VT750M with a new larger VTL.

As Ben Stubberfield continues: \\u201cWe approached Mills CNC with our requirements and were introduced to the new DN Solutions\\u2019 V8300 series. As well as having a bigger work envelope than the VT750M, it also featured the additional side-mounted ATC and the advanced FANUC 0iTP control.\\u201d

As a consequence, the company invested in a new, compact Puma V8300M \\u2013 a machine with live tooling that, despite its small footprint, boasts an 830mm turning diameter and 690mm turning height. Since being installed the V8300M has been put through its paces, machining a diverse range of components made from an equally varied range of materials that include stainless, super duplex, carbon and alloy steels and cast iron. Component cycle times can often be long, depending on the specific application.

Discussing the company, jbj Techniques Managing Director, Mike Davis says: \\u201cEverything we do is geared towards helping customers optimise their processes. From working in partnership with them to design and developing new mechanical power and/or fluid power systems and solutions to supplying replacement parts for existing systems \\u2013 our focus is on helping manufacturers reduce downtime, improve safety and sustainability, and maintain productivity levels.\\u201d

Jbj Techniques\\u2019 customer base and user profile are large and diverse. Its products and solutions are used extensively in the power generation, oil and gas, renewables, motorsport, food and beverage, transport, environmental, materials handling and marine sectors. Wherever mechanical power and fluid power transmission systems are employed, there is a good chance that jbj Techniques\\u2019 products, services and solutions have been implemented.

Jbj Techniques\\u2019 machine shop, comprising seven CNC machine tools and a range of manual machines and equipment, is a vital and integral element of the company\\u2019s service offering and one that helps differentiate it from its competitors.

The latest DN Solutions\\u2019 V8300M VTL has significantly increased machine shop capabilities and has also helped it improve its ability to respond quickly to customers\\u2019 requirements for large and complex high-quality machined components.

Listed in: Business

New tech allows more customisation in growth sector

Like other industries, the UK medical devices sector was heavily disrupted during the Covid pandemic. But in contrast with many, it initially saw a surge in demand for many products, followed by a lull as demand pressures eased. It has now recovered from the 2022 downturn and is resuming annualised growth of over 5%. By Will Stirling

The UK medical devices market, worth over \\u20ac17bn a year, is the third-largest in Europe, after Germany (\\u20ac41bn) and France (\\u20ac31bn) and ranks number six in the world. The size of the market itself is not automatically reflected in the size of its manufacturing sector. The Republic of Ireland, for example, punches well above its market weight in terms of production and is second only to Germany as a European exporter of medical technology. Many companies have opened operations in Ireland in recent years, either production operations or sales and service hubs. These include robot producers KUKA and FANUC, who used to serve the Irish market mainly from their UK bases.

The UK has over 3,000 active device manufacturers and has a strong reputation for orthopaedic, imaging, diagnostics and cardiovascular devices. The market itself is projected to grow by around 5.6% annually from 2024 to 2028, and to reach a value of $22.68bn by then. The total includes in vitro diagnostics but physical medical devices account for over 90% .

Growth is being driven primarily by two factors: customer preference (hopes for improved outcomes) and an ageing population, which requires devices such as artificial joints, mobility aids and home healthcare equipment.\\xa0

Regulatory advantage\\xa0

The UK is becoming an attractive place for non-EU companies to base operations, with the introduction of the new European Medical Device Regulation Directive, according to reports in the pharmaceutical press, such as pharmaforum . The UK still operates under consolidated regulations which, it is argued, provide a less complex route to market entry. Further help comes from the recently launched MedTech strategy, which aims to encourage and stimulate new medical technologies. In 2020, Scotland\\u2019s Medical Device Manufacturing Centre (MDMC) was opened with \\xa33.7m from Scottish Enterprise\\u2019s Advancing Manufacturing Challenge Fund and several universities in Aberdeen, Edinburgh and Glasgow. It focuses on supporting healthcare SMEs with innovation and product development.

OEMs, contract manufacturing\\xa0and device production

Medical device manufacturers generally fall under one of two headings. Those that manufacture their own devices and those that offer a contract manufacturing service. The term \\u2018medical devices\\u2019 covers an array of products, from drug dispensing to CAT scanning equipment, and therapeutic beds. The focus here is on \\u2018hard\\u2019 medical devices, such as surgical instruments and orthopaedic implants.

At one end of the age spectrum are young people needing dental braces; at the other, the leading surgical requirement for over-50s globally is replacement joints \\u2013 hips, especially. Several of Europe\\u2019s top 50 manufacturers of artificial knees and hips have locations in Great Britain and Ireland, including Smith & Nephew, Stryker and Corin Group.\\xa0

Smith & Nephew\\u2019s Redapt cup was its first 3D printed titanium hip implant. It chose additive manufacturing in order to produce an entirely porous implant, which mimics the structure of cancellous or spongy bone \\u2013 the softer bone type that is typically found at the ends of long bones, like hips.\\xa0

A habit of innovation\\xa0

Product innovation is the lifeblood of medical device manufacture. Swann-Morton, founded in 1932 and based in Sheffield, was initially established to make razor blades. Within a few years it became, and has remained, a leading supplier of surgical instruments to the NHS. In the 1960s, in collaboration with the United Kingdom Atomic Energy Authority at Wantage, it developed a sterilisation process using cobalt-60 gamma radiation and built one of the first commercial plants of its kind in the world. More recently, it introduced the KLEEN Blade Management System, which allows for safe attachment and removal of surgical blades from standard handles and the Surgical Blade Remover, which facilitates safe removal of scalpel blades from handles. Swann-Morton\\u2019s products, which include approximately 70 different blade shapes and 30 handle designs, are used by surgeons, GPs, nurses, paramedics as well as practitioners in dentistry, podiatry and veterinary surgery.

Williams Medical Supplies, based in Rhymney, Wales, is the largest supplier to general practices in the UK. It manufactures and retails medical products ranging from surgical instruments to pharmaceuticals. Rocket Medical has a manufacturing base in Washington, Tyne & Wear, an office in Watford and presence in The Netherlands, Germany, USA, Australia and New Zealand. It designs, develops, and manufactures single-use medical devices for various clinical areas, including cardiothoracic, ascites drainage, infertility, and colorectal procedures. In 2019, it invested in a new\\xa0 quality control system from software company Lynq, which enabled it to manage production and inventory more effectively and helped with its growth path.\\xa0

Founded in 1979, JRI Orthopaedics of Sheffield originally distributed hip replacements before going into manufacture, recently marked a milestone with its 100th A3GT total knee replacement. The company also recently celebrated a 100% survival rate of its Furlong H-A.C femoral stem, an implant for aseptic loosening at 27 to 32 years. The device has ceramic coating and was designed especially for younger patients.

Milling, moulding and\\xa0additive manufacturing

\\u2018Hard\\u2019 devices, such as implants especially, are produced either by traditional milling, moulding or additive manufacturing. Attenborough Medical, which was established in 1913, has invested heavily in 3D medical imaging scanning and custom manufacturing techniques to produce implants specifically designed for individual patients. Europlaz, one of the UK\\u2019s leading medical equipment manufacturers, injection moulds medical grade polymers. It has cleanroom manufacturing facilities covering over 9,500 of its 60,000sq/ft manufacturing area, which also includes 24 injection moulding machines with capacities from 10 to 300 tonnes.\\xa0

Traditional strengths

The continued importance of traditional milling is demonstrated by companies like Oracle Precision, which manufactures reconstructive medical devices, associated instrumentation and ancillary components. \\u201cCNC machining makes it possible to produce artificial joints that perfectly fit the patient, giving improved outcomes with joints that last and are biocompatible,\\u201d Oracle said. Oracle uses CNC machining on materials including stainless steel, titanium, medical polymers, elastomers and composites. It offers both one-off and batch medical machining and a full list of technologies: 4 and 5-axis milling, 2D and 3D machining, CNC turning and CMM inspection.

LUBE-FREE BEARINGS GOOD\\xa0FOR MEDICAL APPLICATIONS

Medical technology is becoming lighter, more compact and modular and many medical devices need bearings. igus bearings and linear guides are designed for flexible adjustments and its energy chain systems for safe cable guidance are specially designed for medical applications. These products can be found in X-ray robots, laboratory devices, patient and treatment chairs, hospital beds and prostheses. They are resistant to chemicals, lubrication-free and maintenance-free and therefore offer maximum wearability in daily use. High loads such as shocks must be safely absorbed, and intensive care requires particularly reliable systems with easy and precise adjustability. Safety and ease-of-use are prioritised as all igus medical products are cleanroom compatible, media-resistant, and quiet \\u2013 to meet high medical standards.

Listed in: Business

Mobility manufacturer gets moving with XYZ

XYZ Machine Tools is helping Handicare maintain the accuracy, rigidity and quality of its stairlifts by machining the mating surfaces of its tubular components using an XYZ RMX 3500 for straight sections and an XYZ RMX 4000 for curved sections to achieve a perfect fit.

Handicare is a leader in its industry covering accessibility, patient handling and vehicle accessibility and can trace its roots back to 1886. Its objectives are to offer solutions and support to increase the independence of physically challenged or elderly people and to enable them to live an active life on their terms as well as to facilitate work for their care providers and family.

Handicare\\u2019s headquarters are located in Stockholm, Sweden and it sells its products and solutions globally and is active in more than 40 countries. One of its UK manufacturing facilities is at Kingswinford, Birmingham where it designs and manufactures straight and curved stairlifts, producing more than 50 every day. Each stairlift is bespoke, and designed to fit its customers\\u2019 stair configuration. The key element of each stairlift is a pair of tubular runners with gear racks welded to them. These support the seat and, with its pinion drive and rollers, allow it to transport the customer between floors. Each set is unique and carefully designed to fit the stairwell.

During the design phase of each stairlift, consideration has to be given to handling the tube sections and accessibility for installation and assembly. This means that tubes need to be made in sections ready for on-site assembly. Some shapes for curved stairlifts can be complex, for example moving the seat to a park position around a newel post, so these need particular care during manufacture.

Nabil Mohamed, Production Engineer at Handicare explains: \\u201cFor straight stairlift sections the tubes and gear rack are robot welded together and they are then cut to length. We leave an excess of 0.5mm which is then machined with the XYZ RMX 3500. We do this to make sure that the gear profile on the rack is perfect when we join the tubes. If we didn\\u2019t do this and left a slight mismatch on the gear profile, the customer would feel an uncomfortable jolt every time the seat went over a joint.\\u201d

The XYZ RMX 3500 is dedicated to straight sections and has a set of fixtures on the bed that are designed to lock the gear profile and tubes into position to mill across the end and generate an accurate gear profile and perfect tube length. The open design of the bed mill makes it possible to work with long tube sections that overhang the bed. The machine\\u2019s ProtoTRAK\\xae control has different programs already prepared so that it is easy to select the one required for the fixtures being used.

For curved profile stairlifts, the process is similar with tube sections being machined on the XYZ RMX 4000. This has a larger bed 1474 by 355mm and has fixtures loaded to suit the machining of the ends of curved sections, again locating the tubes on the gear rack to ensure end machining is accurate.

To join tubes, straight sections can be connected with crimped inserts and cross-drilled bolt holes, while curved sections are robot-welded together with an internal collar. Special-purpose machines clamp components together for these operations to ensure on-site assembly goes smoothly before physical inspection and surface finishing.

Nabil Mohamed says: \\u201cEvery component goes through one of the XYZ RMX machines, so they are a crucial part of the process. Their record of reliability is very important to us. Being able to accurately machine the ends of every tube and gear rack is a vital part of the quality, performance and reliability of our products.\\u201d

Listed in: Business

XYZ brings 19 machines to MACH 2024

XYZ Machine Tools will be exhibiting the full range of its TMC machining centres for the first time at MACH 2024. The company will premiere the new XYZ CT65 LTY-S Twin/Sub spindle lathe.

In total, XYZ will have 16 machines under power on its main Stand 140 in Hall 20, right next to the entrance to Hall 20. In addition, it will have an XYZ RLX 780 3m CNC Lathe on a second stand in Hall 6 - Stand 72 with two XYZ 500LR VMCs on the WorldSkills Stand 480 in Hall 17. The XYZ TMC range features the easy-to-use ProtoTRAK\\xae control which delivers simple shop floor programming complete with optional handwheels for manual operation and winding forwards and backwards through the machining cycle.

Built with a solid ribbed casting and the latest linear rail technology, these machines are not much more than an equivalent-sized XYZ bed mill, giving the advantages of the bed mill in an enclosed safe and clean working environment with up to 20 station carousel tool changer. The machines give the versatility to make one-off or small batch parts to full production runs with minimal operator effort.

Making its debut at MACH will be the Box Way XYZ CT65 LTY-S Twin/Sub spindle lathe that brings the advantages of automated one-hit turned and milled components to XYZ\\u2019s customers. The machine can turn parts up to 490mm long and bar feed diameters up to 66mm. With twin spindles, live tooling and Y and C-axis, this machine can turn and mill complex parts at both ends in one operation, dropping the finished part into its part catcher for hours of unattended machining. For heavy-duty machining applications, the XYZ 800 HD includes box slideways and massive ribbed castings for maximum rigidity. Matched with the Siemens 828D control with ShopMill and options for 4th axis rotary tables, this machine has the power and capability to machine the toughest materials.

For full 5-axis simultaneous machining, the XYZ UMC-5X can save hours in setup time especially where 6 sides of a part need to be milled or drilled. With suitable fixturing full machining can be done in just two setups. Repeatability on this machine is \\xb1 2.5 microns with linear scales on the X, Y and Z axes with high-precision encoders on the A and C-axes.

A direct drive high torque 90rpm motor is standard on the rotary axis and an option on the tilting axis. A 15,000 rpm spindle, Dynamic Collision Monitoring and Thermal Spindle Compensation are standard with options for 18,000 and 24,000rpm spindles and Traori hole machining compensation making this a powerful and cost-effective solution which has proved to be popular with aerospace manufacturers.

The stand will also feature the ever-popular RMX Bed Mills, KMX Turret Mills and RLX lathes. These machines can be used manually or under full CNC with their ProtoTRAK\\xae controls. This makes learning and operating the machines very simple.

This year, XYZ Machine Tools is celebrating 40 years since it was founded. It now has over 15,000 machines in daily use in the UK and across Europe where it has an extensive distribution network. It is well known for the reliability and quality of its machines and its after-sales service.

Listed in: Business

Versatile workholding ensures productivity and precision

TecnAir designs and manufactures an extensive variety of pneumatic cylinders, valve assemblies, linear drives, handling equipment, controls and other products. Located in Shipley, the company\\u2019s products are used for the assembly of standard and special automation solutions worldwide, predominantly in the transport, semiconductor, railway, marine and off-shore automotive industries.\\xa0

Characterising this activity above all else is the large amount of metal cutting involved in machining the parts, as well as the extreme accuracy to which they must be machined. To this end, since the early 2000s the manufacturer has entrusted component clamping on its machining centres to Chick workholding products, manufactured in the US and supplied through sole UK agent 1st Machine Tool Accessories.\\xa0

Steve Watson, CNC Operations Manager at TecnAir advised: \\u201cThe accuracy of the sliding surfaces is critical on many of our components, so tolerances down to single-figure microns must be held to ensure they can perform many millions of cycles faultlessly. Similarly, the finish on ground, polished or roller-burnished sealing faces has to be very high, so the flatness and roughness of milled surfaces must be excellent to allow the low Ra values to be achieved as quickly as possible.\\u201d

\\u201cFixturing is crucial, as any movement or vibration cannot be tolerated. Chick products have underpinned the required level of accuracy in our factory for the past couple of decades and continue to do so. Not only is rigid workholding ensured, which incidentally also prolongs tool life, but a high level of interchangeability of the various Chick clamping units also helps to minimise investment in the equipment.\\u201d

Monthly quantities are machined in batches of from 200 to 2,000 for TecnAir\\u2019s products, which account for 80% of turnover. Many thousands of component variants are involved, which are manufactured over a double shift pattern, five days a week plus at weekends if necessary. The remainder of throughput is subcontract design and production of parts for other companies, which involves machining anything from one-offs to a couple of hundred components.

Supporting the prismatic machining operations on the shop floor are 15 Chick QwikLOK units, which are used on five vertical machining centres (VMCs), three from HAAS and two from Yamazaki Mazak. Six of the units are dedicated to pendulum machining of relatively short pneumatic cylinder bodies from aluminium extrusion in three operations \\u2013 rear-end cap machining, front-end cap machining and inlet and outlet port machining on a Mazak VTC-530. The resulting high-density workholding has the effect of maximising the use of the available machining area and reducing the overall number of tool changes needed for machining the components.

In addition, there are 11 MultiLOK towers deployed across three twin-pallet, 4-axis, horizontal machining centres (HMCs). They are a stand-alone Doosan HC400 and two Mazak HCN-4000s linked by a Palletech automated storage and retrieval system for 16 machine pallets. Materials processed are mainly aluminium and stainless steel, plus some brass, with castings accounting for 30% of throughput while the remainder is produced from either billet or extrusion.

The QwikLOKs use three jaws to secure two workpieces simultaneously against a fixed central jaw by turning a single handle, in contrast to a traditional vice that is only able to clamp a single part. Opposing forces are cancelled and a reliable reference point is provided for machining. The Chick jaws create a pull-down action when they close, ensuring rigid workholding. On every face of each four-sided MultiLOK tower, according to the size of the component to be fixtured, there is either a single-station or a dual-station jaw set. These employ Chick\\u2019s proprietary QwikChange snap-on/snap-off interface. Round and diamond pins in two bushed locating holes provide high clamping repeatability, leading to consistency of machining from one batch to the next.

Ideally, for maximum productivity and extended periods of unattended machining, components are set up on all four faces of a Multi-Lok. However, there are occasions when only two or three faces are employed, such as if components are longer than the tower width and overhang one or both sides.

Alternatively, instead of a jaw set, an aluminium faceplate can be snapped in seconds onto the QwikChange interface on any side of the towers. The repeatability of location is within microns, providing what is essentially a zero-point pallet exchange system. The faceplate is pre-machined and may incorporate other workholding devices to configure bespoke fixturing arrangements for securing awkwardly shaped and/or multiple components quickly in a single set-up.\\xa0

The decision to invest in a faceplate depends on the number of components to be produced and the frequency with which batches repeat. At TecnAir, a couple of dozen machined faceplates are stored for suitable jobs. An additional advantage of this approach is that workpieces can be fixtured offline, away from the machine tool, maximising its spindle uptime.\\xa0

It is similarly possible to put a faceplate onto a QwikLOK on a VMC if an application warrants it. Moreover, based on similar considerations regarding quantities of components involved and frequency of production, bespoke machined soft jaws can be held for use on the QwikLOKs to hold securely workpieces of difficult shape, often in multiples, such as round components that would tend to spin in a normal hard jaw set.

Listed in: Business

Sound of Music

Like the \\u2018Sound of Music\\u2019 that has won its place in movie folklore, the 2024 \\u2018Sound of Studer\\u2019 themed event that took place at the company\\u2019s Steffisburg headquarters has won its place in the hearts and minds of the 65 journalists from over 20 countries that attended. The annual Fritz Studer AG event is always packed with the latest innovations in grinding, an insight into the company\\u2019s ongoing evolution and an overview of the global trends in the manufacturing industry - and the February event once again lived up to its billing. By Rhys Williams

Located in the Swiss Alps, in a region more stunning than the backdrop to the legendary movie, the \\u2018Music Motion Meeting 2024\\u2019 kicked off with presentations from the management team and was followed by technical presentations on the latest innovations and an insight into what we can expect to see as we move through 2024.\\xa0

Studer CEO Jens Bleher kicked off proceedings with a presentation that discussed the company\\u2019s performance over the last 12 months, the market turbulence, new updates to the CORE interface, product enhancements and the pride in the success the Swiss manufacturer continues to enjoy with its success at the World Skills event.\\xa0

\\u201cDespite the challenging investment environment, we again increased our sales, especially in key markets like the USA and China. Asia was the largest single region followed by Central Europe and North America and consistent investments in product development and site infrastructure have paid off. We have turned our announcements into reality and improved our market position to strengthen ourselves for the future in the long term,\\u201d the Studer CEO announced.\\xa0

Studer once again won market share in many regions around the world, and it hit a new sales record in its Customer Care segment. Bleher took it as a positive sign for the 2024 fiscal year that the order situation developed exceptionally well towards the end of 2023. Whilst confident that order intake will continue in a positive direction, the CEO was particularly bullish about the expected performance in the second half of 2024 \\u2013 a period when the manufacturer of cylindrical grinding machines will present new technologies.\\xa0

Although the development of incoming orders was weaker in individual markets, such as Germany, China and some Asian countries, other parts of the world saw positive results. At the 2023 event, Turkey and several Eastern European countries were the surprise performers. At this year\\u2019s event, Sandro Bottazzo, CSO at Studer said: \\u201cWe achieved good results in many countries and even posted a new record order intake in some.\\u201d Some of the standout performers were announced as Spain, Austria and Holland, a welcome boost with the headwinds of global uncertainty and inflation faced by some of the manufacturing powerhouse nations.\\xa0

Looking at the industry by customer segments, a point that should be marked as a good barometer of worldwide manufacturing performance for MTDCNC readers was that the aerospace industry once again generated the largest increase in new orders. This industry has now overtaken the declining automotive industry for Studer. The \\u2018tool\\u2019 manufacturing segment remained below expectations with the largest individual segment for the second consecutive year being \\u2018precision engineering\\u2019. \\u201cI am very pleased that our grinding machines are so highly trusted by small and medium-sized enterprises, and that this segment remains strategically important for us,\\u201d explained Bottazzo. The \\u2018mechanical engineering\\u2019 and \\u2018mould & die\\u2019 segments also maintained their critically important positions. The increasing demand for precision cylindrical grinding machines in the semiconductor industry has been marked as very pleasing for Studer with Bottazzo confirming robust semiconductor growth in the Americas and Asia.

The performance of specific precision cylindrical grinding machines and maintaining a broad portfolio remained of particular importance in 2023. Incoming orders for CNC universal cylindrical grinding machines were reported as very solid. The machine with the highest sales volume was the S33, followed by the favoritCNC, the S31, the S41 and the favorit. \\u201cWhen it comes to internal cylindrical grinding machines, it was the third-best year for incoming orders in the company\\u2019s history for the S131,\\u201d said Bottazzo. Orders for the new S100 internal cylindrical grinding machine were also very pleasing and exceeded targets. Whilst 2023 sales volumes didn\\u2019t exceed the 2022 numbers that were reported as the company\\u2019s third-best year on record, the order value was almost on par. This was due to higher-value turnkey solutions and the Customer Care packages reaching record numbers.

Alluding to the Customer Care division, Bottazzo added: \\u201cHere we were able to set a sales record for the second consecutive year. This applies to all business areas from maintenance and service to spare parts and overhauls. Particularly pleasing was the development in Eastern Europe, where Studer now performs service with its skilled personnel in the Czech Republic, Slovakia, Poland, and Hungary.\\u201d This expansion and the incredible growth have lit the way for the company to continue investing in the Customer Care division.\\xa0

In 2023, Studer participated in more than 30 trade shows. At EMO 2023 the company presented three automation solutions for the first time. The arrival of the new insertLoad loader as well as the roboLoad and uniLoad was a paradigm shift for the company and these were prominent during the press tour of the facility.\\xa0

Throughout 2023, the focus remained on the development and advancement of grinding technologies. The S36 external cylindrical grinding machine introduced in May 2022 has proven particularly suitable for components in the e-mobility sector since its arrival. Alluding to this, CTO Daniel Huber added: \\u201cNow, our customers can use all spindle variants and automation solutions without restrictions on the S36. Thanks to the new, powerful grinding spindle with 25kW, it is possible to use particularly wide grinding wheels up to 160mm.\\u201d The S36 fills a gap between the existing S11 and S22 machines and it offers greater spindle and automation variants. This includes integration with the easyLoad and uniLoad systems that permit customers to automate production on the S36. Additional options include the ability to add high-speed grinding with CBN or diamond grinding wheels and the Smartjet system.

Huber also mentioned the success of the new S100 internal cylindrical grinding machine that was introduced in October 2022. Since this introduction, new spindle options have already been added such as the powerful \\xd858mm dressing spindle with more additions planned for further models in the future.

As the company moves through 2024, sales are expected to remain strong with a projected upturn in the second half of the year. This will be set in motion by major exhibition appearances and the arrival of new models for the respective events. The new arrival will be a successor to the popular favoritCNC that will reveal new features. Some features in the pipeline include an angle display of the wheel head, the popular QuickSet setup function and a conventional mode as a manual grinding cycle that permits manual grinding without any programming.

A particular focus for development in 2023 was given to the company\\u2019s C.O.R.E. hardware and software architecture from the UNITED GRINDING GROUP. \\u201cThe C.O.R.E. touch operating panel already allows an unprecedented level of intuitive use. Soon there will be a customisable interface where operators can define and save their workspace,\\u201d explained Huber. Data collection and analysis, as well as new sensors and instruments, were also a focus.

Looking to the future of the business, the CTO added: \\u201cThe issue of sustainability continues to be important. The SmartJet\\xae cooling system developed by Studer already sets new industry standards with its ability to reduce the need for coolant and energy in the grinding process. Demand for high-performance semiconductors is also rising due to e-mobility and photovoltaics. Studer\\u2019s S41 CNC universal cylindrical grinding machine with in-situ X-ray measuring head now sets the standard in wafer manufacturing. It is extremely successful in the market. In the long term, only the machine manufacturers who offer intelligent and efficient machines incorporating the latest technology can be successful,\\u201d summarised the CTO as he reflected on the extensive development activities over the past 12 months.

Obviously, the success of a business is not purely based upon its product lines, but also its very foundations. To reflect upon the internal business activities, COO Stephan Stoll provided an overview, saying: \\u201cThe production mix of the machines manufactured has shifted to more complex systems through 2023. With active procurement management and the normalisation of global supply chains, orders were completed on time.\\u201d Stoll positively assessed the implementation of the joint production strategy within the UNITED GRINDING Group, which provided Studer with significantly improved utilisation.

Major operational projects included investments in automated test stands and manufacturing tools. As one of the very few grinding manufacturers producing high-quality spindles, the expertise for these strategically important machine components has been expanded. Comprehensive structural and logistical measures were further implemented in Steffisburg. This has been bolstered in the internal grinding competence centre in Biel with plans for further growth. Referring to the additional growth, the COO said: \\u201cAfter the considerable investments of the past years, the redesign of our logistics processes and warehouse infrastructure is now imminent. The centrepiece of this project is a central logistics hub with a directly connected container warehouse. The higher efficiency of the fully automated warehouse system will benefit machine production.\\u201d\\xa0

The press was shown a roadmap of the planned changes to the manufacturing facility and how it will streamline production, service and logistics. In conclusion, Jens Bleher emphasised the great importance of well-trained employees. He was very pleased with the recent successes at the prestigious professional championships, SwissSkills. Last year, Studer apprentices Luis Salzmann (1st place, design engineer EFZ) and Noah Rossel (2nd place, automation engineer EFZ) won the gold and silver medals with their outstanding performances. \\u201cSTUDER is represented for the third time in a row at the WorldSkills showcase. We are very proud of this. It confirms our extensive commitment to vocational training,\\u201d concludes CEO Bleher.

This commitment to education was further strengthened with an award presentation at the press event for its research prize, the \\u2018Fritz Studer Award\\u2019.\\xa0 Applicants from several European countries submitted their work and it was Dr. Emil Sauter who won the award and the prize of CHF 10,000. The Fritz Studer Award is aimed at graduates from European universities and technical colleges. \\u201cThe objectives of the research prize are to boost innovation in the machine tool industry with feasible solutions whilst also promoting young technical and scientific talents,\\u201d says Dr Frank Fiebelkorn, Head of Research and Technology at Studer.\\xa0

Numerous theses and dissertations were submitted to Studer and evaluated by a panel of experts consisting of Prof. Konrad Wegener, Inspire Institute for Machine Tools and Manufacturing at ETH Zurich, Dr Hans-Werner Hoffmeister, former head of the Manufacturing Technology department at the Institute for Machine Tools and Manufacturing Technology of the TU Braunschweig, and Dr Frank Fiebelkorn, Head of Research and Technology at Fritz Studer AG. Criteria for evaluating the works included the feasibility of the findings in the mechanical engineering industry, the degree of innovation and quality of the research idea, scientific content, form, and the accuracy of statements, and the results and findings.\\xa0

The Fritz Studer Award 2023 was presented to Dr. Emil Sauter from the Institute for Manufacturing Technology and Machine Tools at ETH Zurich. He impressed the entire jury with his topic. \\u2018Detection and avoidance of thermal damage for high-performance metal grinding processes using hybrid machine learning models.\\u2019

His work deals with the development of an innovative condition monitoring system for external cylindrical grinding with metal-bonded CBN tools, which recognises thermal damage in situ and predicts the remaining useful life of grinding tools with relative accuracy. Process parameters such as structure-borne noise, spindle current and force characteristics can be identified. With time-frequency transformations, the research identified features of a process to detect different stages of thermal damage. The remaining tool life can also be estimated. In general, this work with its many industry-oriented practical tests also shows that machine learning methods can lead to higher productivity and improved component quality. Whilst MTD magazine extends its congratulations to Dr Emil Sauter, we also applaud Studer for creating a platform for the engineers of tomorrow.

Listed in: Business

The impact of ESG reporting on manufacturers

The introduction of mandatory ESG (Environmental, Social, and Governance) reporting is set to have significant implications for engineering businesses. Keith Davidson, Environment Partner at law firm Irwin Mitchell discusses how the upcoming ESG developments, starting in 2024, will fundamentally change the business landscape for engineering companies.

Recent and expected ESG developments

Although the term ESG (Environmental, Social and Governance) has been commonly used since 2004, it has not been a priority issue for most SMEs. ESG is used as a measure of socially responsible investing and for the last two decades ESG has primarily concerned international financial market participants such as investment funds, banks, insurers, pension funds and listed companies.\\xa0

Significant changes are on the horizon. The business landscape is set to undergo a transformation in the coming years due to three key developments:

\\u2022 The introduction of the first-ever internationally comparable accounting standards for accounting periods beginning in January 2024, so companies worldwide will be judged according to their ESG performance.

\\u2022 Mandatory ESG reporting has been introduced for large companies in the EU from 2024, and the rules will gradually extend to non-EU enterprises that do business in the EU.

\\u2022 Increased legal obligations to manage supply chain ESG performance, specifically addressing Scope 3 greenhouse gas (GHG) emissions from upstream and downstream value chains.

New global standards for sustainability and climate-related disclosures

On 26 June 2023, the\\xa0 International Sustainability Standards Board (ISSB) launched two international disclosure standards that become effective for accounting periods beginning on or after 1 January 2024: IFRS S1 General Requirements for Disclosure of Sustainability-related Financial Information and IFRS S2 Climate-related Disclosures. IFRS S2 requires the reporting of Scope 3 GHG emissions. \\xa0

It is up to each country to endorse IFRS standards. The UK is currently consulting on the creation of UK Sustainability Disclosure Standards (SDS), which will address this matter. A decision is expected by July 2024. The Department for Energy Security and Net Zero launched a call for evidence in December 2023 to help inform the government\\u2019s decision on whether to endorse the ISSB\\u2019s standards in the UK.

Increased mandatory ESG reporting\\xa0

Since 2015, the Non-Financial Reporting Directive (NFRD) required reporting of certain non-financial and diversity information by very large public-interest entities in the EU with more than 500 employees.\\xa0

The CSRD entered into force on 5th of January 2023 and extends mandatory ESG reporting for a much broader group of companies. This includes non-EU companies that do business in the EU.\\xa0

The CSRD is being implemented in phases.\\xa0

\\u2022 The first phase started in January 2024 and is applicable to listed companies in the EU with over 500 employees already subject to NFRD, with reports due in 2025.\\xa0

\\u2022 The second phase will start on 1 January 2025 and will be applicable to EU companies with at least two of the three following criteria (a) more than 250 employees, (b) a net turnover of more than 40 million Euros and/or (c) a balance sheet of more than 20 million Euros, with ESG reports due in 2026 on 2025 data.\\xa0

\\u2022 Third country undertakings (including UK companies) with net turnover above 150 million Euros in the EU and who have an office or subsidiary in the EU must report in 2019 based on 2018 ESG data.\\xa0

CSRD organisations need to report according to new European Sustainability Reporting Standards (ESRS) which includes Scope 3 value chain emissions.

Corporate Sustainability Directive

On 14th of December 2023, a consensus was reached between the EU Council and Parliament on the Corporate Sustainability Due Diligence Directive (CSDDD), which requires companies to identify and prevent actual and potential adverse human rights and environmental impacts.\\xa0

The new due diligence duty extends to large companies\\u2019 own operations and their subsidiaries and supply chains. The CSDDD will apply to EU enterprises with over 500 employees and a global annual turnover exceeding 150 million Euros and non-EU enterprises and parent companies with over 150 million Euros generated in the EU. There are lower thresholds (250 employees and 40 million Euros) for \\u2018high impact sectors\\u2019 \\u2013 textiles, clothing, footwear, food manufacture, agriculture, construction and mineral extraction.\\xa0

Failure to prevent or end adverse impacts can result in contractual relationships with suppliers being terminated. National supervisory/regulatory bodies will have the authority to impose penalties on companies not complying with due diligence processes with potential fines up to 5% of the company\\u2019s global turnover. There is also the risk of civil liabilities where NGOs and trade unions will have five years to bring a claim.\\xa0

Although an agreement of the draft text has been reached, there is not yet an agreed date for the application of CSDDD and the final text could still be changed. It is forecasted that CSDDD will enter into force during 2024 and will start to apply to large companies around 2027.

Requirement for doing business

CSRD requires the management of Scope 3 value chain GHG emissions and CSDDD will introduce a new due diligence duty to minimise adverse environmental and human rights impact throughout a company\\u2019s international supply chain. Larger companies subject to ESG and carbon reporting will request evidence of climate action and ESG performance from its\\xa0 value chain.

Failure to produce ESG policies and strategies could result in SMEs losing key customers and missing out on new business opportunities. It\\u2019s no longer a \\u2018nice to have\\u2019, ESG will become a requirement for doing business.\\xa0

Access to finance\\xa0

ESG performance is expected to have a substantial impact on access to finance in the future. Compliance with ESG standards will increasingly be requested and monitored by lenders, investors, competitors, civil society organisations and employees.\\xa0

Management systems

To get prepared for CSRD and CSDDD, companies will need to ensure that there are proper governance procedures and processes in place to measure and manage ESG issues. A management system approach will ensure continual improvement. Engineering companies are well placed for this approach as many have already implemented ISO: 14001 and ISO: 45001.

Due diligence in transactions

There will be increased demand in M&A transactions for ESG desktop searches and audits as part of technical due diligence and the need for ESG and climate clauses in legal documentation.

ESG real estate strategy

A large part of a company\\u2019s impact on the environment and the enjoyment of its workforce relates to the quality of its real estate assets. There will be an increased demand for \\u2018grade A\\u2019 accredited space and \\u2018Net Zero\\u2019 buildings and every stage of the property\\u2019s lifecycle from design, acquisition, occupation and disposal will need to consider sustainability issues. There will be a greater use of green leases and the focus needs to shift from data sharing to collaboration between landlords and tenants in terms of planning and costing of works.

Companies will be judged on ESG pledges

CSR (Corporate Social Responsibility) policies were often seen as a polish for corporate reputation. Now that ESG metrics and disclosure standard have been agreed in ESRS and IFRS and ESG performance can be compared between companies, ESG reports will be subject to greater scrutiny and ESG commitments must be put into action.

Listed in: Business

SME reorganises its entire production processes

As a Swiss SME that has thoroughly examined its production from a digital perspective, Sistag AG has recognised the potential of bits and bytes. The company has modernised its facility with a Flexible Manufacturing System (FMS) from Fastems and this approach is yielding interesting results with new experiences and ambitious plans.

The globally active Sistag AG, headquartered in Eschenbach in the Canton of Lucerne, manufactures isolation valves for a wide range of industries. This includes pulp and paper, food and beverage, wastewater treatment and biogas/chemical plants. \\u201cIn addition, we specialise in knife gate valves, known under the brand name Wey Valve. These valves are used in the petrochemical, oil production, and mining industries. Our mechanical production here employs around 165 employees, producing approximately 25,000 to 30,000 knife gate valves annually,\\u201d says Manuel Schmidlin, Head of Manufacturing at Sistag.

Like many other Swiss SMEs, Sistag faces high manufacturing costs. Manuel Schmidlin notes: \\u201cLand is expensive and labour costs are high. Moreover, finding skilled workers for production is challenging, so we have increasingly focused on in-house training.\\u201d To economically produce and manufacture, machines at Sistag must run almost non-stop. \\u201cWe also have the advantage of being particularly strong in the field of special valves. Due to the relatively high level of automation here at Sistag, we can also compete in terms of pricing,\\u201d adds Schmidlin.

The housings, a core component for knife gate valves, are manufactured on two horizontal machining centres. In 2005, the company invested in an FMS from Fastems, specifically a Multi-Level System (MLS), initially connected to an OKK HM 630. In 2010, the system was expanded to a total length of 35m, with a second OKK machine of the same type added.

In 2022, Sistag decided to modernise the MLS. Manuel Schmidlin explains: \\u201cThe electronics were still running on 32 bits, and the system was essentially at \\u2018End of Life\\u2019 with no replacement parts available. During the upgrade to a 64-bit system, we conducted a complete retrofit, both in terms of controls and mechanics.\\u201d As Sistag has been pursuing a consistent digitisation strategy for about four years, the FMS was not only updated with the Manufacturing Management Software (MMS) from Fastems but also placed a significant focus on digitising the entire production facility.

According to Manuel Schmidlin, the company has primarily grown historically in its 60-year history. Sentences like \\u2018We\\u2019ve always done it this way\\u2019 has been heard by the production manager many times.

\\u201cOur projected business has significantly increased. When a customer orders valves today, it\\u2019s not three or four, but immediately 400 or 500. With our existing infrastructure, we were not able to plan such large orders efficiently from start to finish. We had great difficulty keeping our machine capacities and we had no overview of what was happening at what time and where the priorities were. Therefore, our goal was to control our entire production with MMS as a central MES (Manufacturing Execution System).\\u201d

\\u2018The Terra Incognita\\u2019 of A Manufacturing Organisation

The MMS from Fastems provides all the prerequisites for this digitisation approach, as it is currently one of the most powerful solutions for planning, running and monitoring automated machining production. The MMS automatically plans production up to 96 hours in advance while considering all necessary resources, such as raw materials, NC programs and tools, including their tool life.

Manuel Schmidlin is fully aware that for consistently planned production, standalone machines, manual workstations and inspection stations must eventually be included in the whole digitisation process, in addition to the automated equipment. Not an easy task, as these areas are often still a \\u2018Terra Incognita\\u2019 in a usual manufacturing organisation. Nevertheless, this situation is set to change at Sistag with the implementation of a Fastems MES solution for non-automated equipment \\u2013 Work Cell Operations (WCO).

Listed in: Business

Quantum leap in accuracy

At the R\\xf6hm GmbH plant in Sontheim Germany, 750 employees manufacture technology-oriented solutions for the automotive industry, mechanical engineering and aerospace sectors in a 41,000sq/m facility. The parts in question are finished on Kellenberger Premium grinding machines.

The company\\u2019s portfolio fits perfectly with the existing business areas of Rothenberger Holding, which generates a sales volume of \\u20ac1.3billion with over 100 operating companies, many of them in the machine tool sector. Applying an extensive restructuring project, an investment sum of several million Euros was made available, which flowed into new machinery and systems. The aim for the future was to produce R\\xf6hm\\u2018s high-tech products with even better quality and at the same time more cost-effectively.

For division manager Alexander Scheitenberger and his 35 staff members, the investment came exactly at the right time. Scheitenberger\\u2018s department manufactures tool clamping systems, 40% of which are customised special designs. A trained industrial mechanic, Scheitenberger has been with R\\xf6hm since 1990 and is very familiar with all machining processes and the R\\xf6hm portfolio, which includes drill chucks, centre punches, lathe chucks and vices, robot gripping technology, power chucks, clamping cylinders, mandrels and tool clamping systems.\\xa0

The parts were machined on a KEL-VARIA universal grinding machine with a centre width of 1m, which had been in use for 18 years. With spare parts for key components no longer available, making a replacement investment became unavoidable. Scheitenberger and head of production Erhard Bader agreed, that the new machine should again be a KELLENBERGER. \\u201cWe have had a very good experience with the KEL-VARIA. The reliability, accuracy and process safety of the machine over the runtime were outstanding. In addition, the cooperation with KELLENBERGER has always been characterised by a high level of professionalism. Erich Ziegler, the KELLENBERGER area manager who is responsible for us, gave us excellent advice on the new procurement.\\u201d Since 2018, the KELLENBERGER product portfolio has offered two machine designs, which can meet the machining tasks at R\\xf6hm. The new KELLENBERGER 100 platform concept proved to be the best solution, especially as Swiss manufacturer Wenger had specially adapted automation to the machine.

The task assigned to the engineers in St. Gallen, Switzerland, regarding the KELLENBERGER 100 was to develop a platform on which different machine concepts could be realised with a strong customer orientation. The segment of high-performance, low-cost grinding machines within the group was integrated into the concept. The modular solution on a common platform and a new assembly concept to reduce throughput time enable cost-efficient production of the machine and thus a very good price/performance ratio.\\xa0

The KELLENBERGER 100 offers the widest range of standard configurations for a variety of grinding operations. The machine is available in centre widths of 1,000/600mm and a centre height of 200mm and is designed for part weights of up to 150kg. A higher drive power for the grinding wheel (11,5kW) ensures increased productivity, while the newly designed guide in the Z-axis brings greater profile accuracy. For higher accuracy in non-circular grinding, the C-axis is equipped with a direct drive. R\\xf6hm opted for a machine with a centre width of 1m.

The K100 has a compact, collision-free tandem grinding head with motor spindles. Ten grinding head variants are available for the optimised design of the machine concerning the machined parts. The reinforced casing allows the largest grinding wheel diameters for internal grinding up to 125mm.\\xa0

The user-friendly, ergonomic design of the KELLENBERGER 100 machine is complemented by intuitive operator guidance via touch screen interface. The machines are equipped with a state-of-the-art FANUC 31i CNC control with a 19\\u201d touch screen. Various ready-made software packages are included as standard or can be added as an option. They cover simple workpieces, complex workpieces in the shortest machining time, and complex contours and profiles.

Swiss automation specialist Wenger has custom-designed the loading solution WeFlex for chucks and shaft parts, especially for the K100. The WeFlex loader enables automated processing of shaft parts from \\xd86 to 100mm with a length from 20 to 600mm with a maximum gripper diameter of 80mm with workpiece weights up to 5kg in alternating mode and 15kg in single part mode. Interchangeable gripper heads facilitate quick changeover between the shaft and chuck parts. In the stacking module, 8 pallet spaces of size 400 by 600mm are available. Inserts for shaft or chuck parts can be inserted in the pallet frames.

The machine is loaded via telescopic line gantry and an automatic hatch closes off the machine room during machining to ensure the thermal stability of the machine. Directly at the infeed, electricity and compressed air are recorded, which allows the energy consumption of the WeFlex to be recorded and visualised. To reduce energy consumption, the speed of the WeFlex is automatically adjusted to the cycle time of the processing machine. An image-guided setup wizard assists the operator when changing over to a new workpiece. Wenger Managing Director Michael Wenger supervised the initial commissioning, which was followed by training for the R\\xf6hm employees at KELLENBERGER. One week after machine commissioning, the 3-shift operation was resumed. \\u201cThe reliability of the loader works is very high and we haven\\u2019t had any downtime so far,\\u201c reports Alexander Scheitenberger.\\xa0

The service package also includes remote maintenance of the machine and minor service work is handled internally at R\\xf6hm. \\u201cA couple of our employees have undergone service training with a focus on the new machine, so they can carry out minor repairs themselves,\\u201c says Scheitenberger. \\u201cThere is no need to call the KELLENBERGER service team for a minor issue. But if you do need the service, it\\u2019s fast and reliable.\\u201d

The conclusions of Alexander Scheitenberger and his colleagues are very positive: \\u201cIn terms of accuracy, the new machine has brought us a quantum leap. Today, we grind with an accuracy of 2 microns with process reliability. The surface quality of the machined tool clamp is so good that, with the same polishing times, the results are many times better, from Ra 0.3-0.4 microns to below Ra 0.1. Due to the larger grinding wheel and because the new machine is simply faster than the old one, we have a 25% increase in productivity. In addition, personnel costs are 30% lower as the automation ensures that one operator is sufficient for two machines.\\u201d

Listed in: Business

Out of this world!

A total of 16 machines, including a number making their UK and MACH Show debuts, plus two automated manufacturing cells and a complete Mills\\u2019 technology line-up will be on the largest stand at the event.\\xa0

In Hall 19 on Stand 110 Mills CNC, the exclusive distributor of DN Solutions\\u2019 and Zayer machine tools in the UK and Ireland is promising to make MACH 2024 a truly inspiring and transformative event.

With a reputation for always \\u2018pushing the boat out\\u2019 at previous MACH shows the company is doing something similar, confirming that it will be showcasing a total of 16 machines on its 750sq/m stand. The company\\u2019s technology line-up at the event includes eight milling machines which will be seven DN Solutions\\u2019 3 and 5-axis vertical and horizontal machining centres, a large-capacity Zayer horizontal CNC bed mill, seven DN Solutions\\u2019 lathes and turning centres and a DN Solutions\\u2019 SMX multi-tasking mill/turn machine.\\xa0

Two of the turning centres being showcased form the mainstay machine tool elements of two separate automated manufacturing cells. This inclusion demonstrates the growing popularity of Mills\\u2019 automation solutions and their importance to the company\\u2019s future growth ambitions. With a focus on innovation and automation, Mills\\u2019 eagerly-anticipated MACH 2024 theme, currently being rolled out, will not disappoint and is quite literally \\u2018out-of-this-world\\u2019.

\\u201cOur stand at MACH 2022, with its Broadway theme, raised the bar in terms of creativity and stand design,\\u201d says Tony Dale, Mills CNC\\u2019s CEO. \\u201cAs part of our commitment to continuous improvement, we are confident that we have \\u2018gone one better\\u2019 this time around with our MACH 2024 \\u2018SPACE ODYSSEY\\u2019 themed stand.\\u201d

Five of the machines on Mills\\u2019 stand are new models that are making their MACH show debuts. Occupying the largest space on Mills\\u2019 stand will be the new Zayer XIOS G CNC horizontal bed mill. This large-capacity machine is equipped with a built-in rotary table 1500mm by 1500mm, a 5-axis, 45-degree milling head and the latest Heidenhain control. With its powerful, high-torque 40kW 6,000rpm spindle and impressive positional accuracy of 0.008mm and repeatable accuracy of 0.005mm, the XIOS G is ideal for large aerospace, rail, energy and oil and gas part processing.

New DN Solutions\\u2019 machines making their MACH 2024 debuts include the compact, FANUC-controlled DVF 4000 simultaneous 5-axis machining centre, the DNT 2100M and DNT 2600 models from the recently-launched DNT-series of high-performance lathes and a V 9300M vertical turning lathe. The DVF 4000 is the latest addition to DN Solutions\\u2019 popular DVF series of simultaneous 5-axis machining centres and is equipped with a 12,000rpm spindle, a 400mm diameter, a built-in rotary tilting table and a 60-position ATC.\\xa0

The FANUC-controlled DNT 2100M has an 8\\u201d chuck/65mm bar diameter and is equipped with an 18.5kW 4500rpm spindle, a 12-station turret and driven tooling capabilities up to 10,000rpm. The DNT 2600 is a 10\\u201d chuck with 81mm bar diameter, equipped with a 26kW 3,500rpm spindle and 10-position turret.\\xa0

The V 9300M is a robust and powerful 24\\u201d chuck vertical turning lathe with 20m/min rapids, a 45kW 1800rpm spindle, a 12-station turret, 4,000rpm driven tooling capability and an additional, front-mounted ATC.

In addition to new machines making their debuts, Mills\\u2019 stand also features several popular and best-selling models from its well-established machining centre, turning centre and mill-turn machine ranges.

Mills will also show the DVF 5000 simultaneous 5-axis machining centre and to emphasise its future importance to the company, Mills is showcasing two DVF 5000\\u2019s on its stand \\u2013 one standalone model and one integrated with a multi-level automated pallet change system.

Other milling favourites being exhibited include three DNM vertical machines centres, a DNM 4500 with Siemens control

\\u2018Ad Astra\\u2019: Automated\\xa0robot cells\\xa0

In recent years, Mills CNC has gained a reputation for supplying manufacturers with productivity-enhancing automated manufacturing cells. At MACH 2024, the company is reinforcing its automation and turnkey solutions\\u2019 pedigree and credentials by showcasing two robot cells on its stand. The first of these \\u2013 a SYNERGI Premier cell comprises a 12\\u201d chuck Puma 3100SY sub-spindle, Y-axis turning centre integrated with a FANUC industrial robot, a five-drawer part load/unload station and a 17\\u201d touchscreen iHMI.

The cell is driven by Mills\\u2019 proprietary SYNERGi software. The second cell incorporating a compact 10\\u201d chuck Lynx 2600SY sub-spindle Y-axis lathe is integrated with a cobot and this will be undertaking a range of machine tending operations.

Concludes Tony Dale: \\u201cVisit us at MACH 2024 for a true voyage of discovery. We\\u2019d b

Listed in: Business

NCMT celebrates 60th anniversary at MACH 2024

NCMT is celebrating its 60th anniversary this year. In 1964, it was one of the first companies to sell CNC machine tools into the UK and Irish markets when it won the sole agency to sell and service Makino machining centres. Twelve years later, a second agreement was reached with Okuma, another Japanese manufacturer.\\xa0

In 2005, Makino-NCMT Grinding Division was established to develop and sell throughout Europe Makino machining platforms for creep-feed VIPER grinding of nickel alloys. Since 2015, NCMT has also been the Europe-wide agent for photo-activated adhesive workholding systems manufactured by Blue Photon in the US.\\xa0

NCMT has now signed an exclusive distribution agreement with Tritone Technologies, an additive manufacturing (AM) technology specialist in metal and ceramic applications. Typical AM parts will be available with representation on Stand 130 in Hall 19.

Rigid, thermally stable construction protects the Okuma Genos M560-V-e VMC from deformation, resulting in high machining performance for an entry-level machine. At the show, the 3-axis machine will be equipped with a Cellro X20 robotic.

The M560-V-e has a 1,050 by 560 by 460mm working envelope and a maximum table load of 900kg. The 15,000rpm BT40 spindle moves in the X and Z axes, with the table moving in Y. A 32-position tool magazine is provided. Software can be added, including Machining Navi to minimise chatter by finding the best cutting conditions. It employs a microphone to detect the onset of vibration and feeds information back to the control.\\xa0

The popular Genos M460-5AX VMC will also be at MACH and will be one of the first Okuma machines to be exhibited in the UK with the manufacturer\\u2019s new OSP 500 control. It was the original 5-axis machine in Okuma\\u2019s economical, series-built Genos range. The trunnion with a rotary table and 5-axis simultaneous control gives the machine the ability to produce highly complex components. The BT40 spindle is rated at 15,000rpm 22kW, which is served from a 48-position tool magazine. Features such as Okuma\\u2019s 5-axis auto-tuning system that accurately fine-tunes the geometry of the machine for ultra-high precision, and Okuma\\u2019s Absoscale linear encoders in the X, Y and Z axes, are all part of the standard specification.\\xa0

The competitively priced Genos L3000-e-MYW lathe from Okuma will be at MACH, fed automatically with shaft-type parts by a Cellro CoMate cobot. Maximum turning diameter is 300mm and the rotational speed of the 22kW spindle is up to 3,800rpm, all in a compact footprint of 2.5 by 1.9m. The turning centre has a sub-spindle and a 12-station turret with Y-axis and live tooling.\\xa0

With a 240-degree swivelling B-axis head and HSK-A63 (optionally Capto C6), 12,000rpm 22kW spindle for turning or milling components up to 1,500mm between centres, an Okuma MULTUS U3000 multi-tasking lathe will be demonstrated on the stand. The tool magazine has 40 stations as standard but is optionally available with a capacity of 80 tools.\\xa0

The machine is fitted with Okuma\\u2019s linear scales for high-accuracy positional feedback. Servo motors deliver feed rates of up to 50m/min in the X and Z axes, 40m/min in the 250mm Y-axis. Together with the C-axis on the main spindle, the machine is capable of fully interpolative, 5-axis (X, Y, Z, B, C) machining of freeform surfaces.

Next-generation\\xa0Okuma control

The OSP-P500 CNC system, manufactured in-house by Okuma along with virtually everything else on its machines, will be on show for the first time in the UK. It combines highly productive and precise machining with ease of use, energy efficiency and safety features to protect against cyber-attacks. Particularly well suited to high-speed machining applications and achieving top-quality surface finishes, the CNC has twice the computing power of conventional machine control, shortening cycle times by up to 15%.

An on-machine Digital Twin facilitates high-precision simulation of machining processes, reducing set-up times and speeding production. By performing these simulations on the machine itself, production can start immediately afterwards.\\xa0

Ultra-fast 5-axis\\xa0

In a space on the shop floor of less than 3.3sq/m, the N2-5XA horizontal machining centre from Makino is capable of very high-speed machining of components up to 300mm diameter by 270mm high and weighing a maximum of 30kg, including fixtures. The machine is ideal for fully interpolative, 5-axis machining of complex components.\\xa0

Within its working volume of 300 by 300 by 230mm, the horizontal spindle design ensures that gravity assists swarf removal, prolonging tool life by avoiding the recutting of chips that are frequently harder than the parent material.

The show will also mark the first UK appearance of the Makino DA300 5-axis, trunnion-type, VMC configured as a production cell with 40 pallet positions on five levels for extended periods of lights-out running. Maximum workpiece size is 360mm diameter by 300mm tall for the eight positions on the top row of the store and 280mm tall on all other levels. Maximum payload per position is 60kg. The automation package includes an integrated chuck, pallet interface and Single Pro6 graphically-driven cell controller, via which it is easy to manage the machine and pallet system.\\xa0

Makino\\u2019s U6 H.E.A.T. Extreme wire-cut EDM centre will be on show. In addition to using standard wire from 0.1 to 0.3mm, it is optionally possible to run the largest diameter wire of any machine on the market at 0.4mm. The wire is coated and distinct from the uncoated brass wire that is commonly used in industry.\\xa0

Part of Makino\\u2019s popular U-Series wire EDM machine platform, the U6 H.E.A.T. Extreme uses Bedra copper core wire with a double-layer coating having controlled zinc donation. It has been optimised for use with Makino\\u2019s generator and is exclusive to the new machine, promoting fast cutting at a reduced wire speed, leading to lower manufacturing costs. Areas of application include aerospace and medical component machining, separating additively manufactured parts, machining tall moulds and dies and tackling tough nickel alloys.

The Makino EDAF3 die-sinking EDM machine on the stand features a rigid, precise structure and integral thermal cooling of the Y- and Z-axis cast components to ensure long-term accuracy. Table size is 700 by 500mm and the dielectric reservoir is built into the base casting of the machine to improve stability and minimise the footprint. The machine uses Makino\\u2019s latest Hyper-i control, which can be factory-ordered mounted on either the left or right, facilitating easy integration of one or more machines with a variety of commercially available electrode and work pallet handling robots.\\xa0

Exhibited on the stand will be the Blue Photon photo-activated adhesive system. The method is ideal for securing awkwardly shaped parts to allow maximum access to tools for tight-tolerance machining or inspection. The process involves applying an adhesive that is cured by ultraviolet light via an LED spot-curing system. After machining is complete, the adhesive contact points can be sheared to free the workpiece by rotating the gripper pins in the fixture plate with a spanner. The residual adhesive can subsequently be removed by the application of hot water.

Listed in: Business

ITC provides complete solution for composite experts

As a company that has continually evolved over the last 40 years to become a leading global force in composite and GRP development and manufacturing, KS Composites is at the very cutting edge of innovation. KS Composites pushes the boundaries in the motorsport, marine, energy, rail, aviation and defence sectors and the Melton Mowbray company relies upon the expertise of the cutting tool experts at Industrial Tooling Corporation (ITC) to deliver results.\\xa0

Operating out of a 48,000sq/ft manufacturing facility that accommodates more than hundred staff, KS Composites services and facilities include everything from design and manufacture to FEA, CFD, kit cutting, wet clay composite shop, autoclaves and ovens, fitting and assembly and a modern machine shop. Some of the company\\u2019s recognised clients and projects include the Jaguar Project 8, Revolution Racecars and a multitude of prestigious F1 projects.\\xa0

KS Composites has a longstanding relationship with Tamworth-based ITC, Dan Johnston, Business Development Manager at KS Composites alludes to why the company continues its relationship with ITC: \\u201cWe use ITC cutting tools due to the great working relationship we have with the team and the longstanding great service we receive. Whether discussing new advancements in tooling technology or looking at building up a package of tools to support a project, ITC has always given us great advice. Even better is the on-site support in running tooling trials to confirm that tooling works as stated.\\u201d

Looking at the cutting tools KS Composites use, Dan continues: \\u201cWe use a large variety of ITC tools from face mills, endmills, bullnose, ball nose endmills, drills and taps amongst other niche tooling. This variety of tooling is needed to support the many different items we machine, including but not limited to patterns, moulds, jigs, components, inserts, props and models. Add into this mix that we machine an array of materials and it is very clear that we need a tooling supplier with a huge variety of options. We also have an onsite vending solution from ITC with a comprehensive stock level that ITC keep fully serviced to support our business.\\u201d

Looking at the cost savings derived from the ITC range of cutting tools, Dan Johnston adds: \\u201cWhen we conducted a full cost analysis of our tooling and the total material removed, it\\u2019s clearly evident that the ITC tooling is great value for money. We have managed to control costs over the years and ITC has helped to improve efficiencies whilst enabling our business to embrace the very latest tooling technology for composite machining.\\u201d

\\u201cOn more than one occasion, ITC has gone above and beyond to give full technical support in the implementation of new tooling, applications and machining strategies. When presented with a new material which we had very little knowledge of, ITC built a bespoke suite of tooling and trials to support our ambitions to effectively and efficiently machine the new material. The results have proven extremely encouraging and this certainly went a long way in building our confidence in working with that particular material.\\u201d

Listed in: Business

Insert evolution continues to take shape

The introduction of the ISCAR HELIMILL in the 1990s marked a significant milestone for milling tools. It revolutionised the design of milling tools with indexable inserts, establishing a new approach that would shape the industry for years to come.

This breakthrough was achieved using a parallelogram-shaped carbide insert, featuring a helical cutting edge formed by the intersection of the insert\\u2019s helical side and shaped top surfaces (Fig. 1). The HELIMILL concept offers several advantages.

Firstly, the consistency of the rake and relief angles along the insert cutting edge when mounted on a tool reduces cutting force variations and ensures a smooth cutting action. Secondly, the uniformity of the insert cutting wedge enhances its strength. Lastly, the helical cutting edge\\u2019s proximity to the imaginary cylinder generated by a rotating tool improves accuracy compared to the straight edge found in previous-generation milling inserts. These advancements elevated milling performance to new heights.

Over the years, continuous improvement has led to significant changes in the classical HELIMILL inserts. The helix of the cutting edge has become more aggressive and the top surface topology has become more intricate. Combined with advanced carbide grades, these new designs have ushered in a new level of performance. However, the parallelogram insert shape limits the number of indexable cutting edges to two.

To maximise the efficiency of cemented carbides, a new round of insert development was initiated. The successful adaptation of the helical cutting edge to triangular inserts addressed this limitation. The triangular insert concept not only provides three cutting edges but also offers additional benefits. When compared to other shapes with equal cutting-edge lengths, the triangular shape provides a wider central area. This allows for an increase in the central bore size, enabling the use of a clamping screw with a larger thread. As a result, the insert security is strengthened, contributing to the overall durability of the milling tool assembly. Additionally, the triangular shape enhances the ramping-down cutting capability.

Overall, the introduction of the ISCAR HELIMILL and its subsequent advancements have advanced the milling tool industry. The use of helical cutting edges and triangular inserts has significantly improved performance, accuracy, and durability, pushing milling capabilities to new levels.

A proximate successor to the HELIMILL is the HELI-3-MILL, a family of milling tools introduced by ISCAR in the last decade, featuring triangular indexable inserts (Fig. 2). The advantages of the \\u2018helical triangle\\u2019 highlight why this family has gained popularity in the market. However, it is important to note that this does not mean the triangle shape will completely replace the traditional parallelogram contour with helical cutting edges any time soon. The parallelogram shape still possesses its competitive edge.

Paradoxically, the narrow width of the parallelogram-shaped insert, which is considered a drawback when compared to the triangular shape, also offers certain advantages. Firstly, a narrower insert allows for an indexable design suitable for smaller tool diameters. Secondly, this insert geometry reduces the depth of the chip gullet, strengthening the cross-section of the tool body. This feature is particularly important for extended flute cutter designs where higher strength and rigidity of the body are crucial.\\xa0

The parallelogram insert structure also permits increased corner radii. Additionally, the classical shape is well-suited for high feed milling (HFM) inserts, which can be mounted in existing pockets, effectively transforming a 90-degree tool into an efficient HFM cutter. Moreover, the \\u2018helical parallelogram\\u2019 has a smaller overall length compared to the \\u2018helical triangle\\u2019 for the same cutting length. Therefore, it would be premature and incorrect to dismiss classical parallelogram inserts.

As a result, the development of 90-degree indexable milling cutters harmoniously combines both approaches, utilising both triangular and parallelogram-shaped inserts. While the triangular insert concept dominates modern designs, the parallelogram insert principle remains relevant. The HELIMILL platform continues to be updated with new advantageous products. ISCAR\\u2019s recently developed products related to milling cutters with parallelogram-shaped inserts demonstrate that the traditional design approach remains effective and capable of meeting the demands of modern manufacturing. Milling high-temperature superalloys and titanium (ISO S group of applications), as well as difficult-to-cut austenitic and duplex stainless steel (ISO M group), present challenges. Effective coolant supply, particularly pinpointed high-pressure cooling (HPC), can significantly reduce the heat load on the cutting edge, enhancing lubrication and chip removal.

This, in turn, leads to higher cutting data and enables larger radial engagements, resulting in a higher metal removal rate (MRR). Moreover, HPC facilitates the production of tighter curled chips, allowing for tool designs with smaller chip gullets and higher tooth density. Taking these factors into consideration, ISCAR has expanded its HELI2000 family (the latest version of the HELIMILL) by introducing new tools that incorporate the HPC option within the tool body. The design of\\xa0 these tools has been optimised using computational fluid dynamics (CFD). They are available in both integral-body configurations and as relatively small-sized exchangeable\\xa0 \\xa0 heads with indexable inserts, which are compatible with ISCAR\\u2019s modular systems MULTI-MASTER and FLEXFIT (Fig. 3).

HELI2000 integrates the HELIMILL and HELIPLUS families, combining their latest developments into a single portfolio. This includes the introduction of two new highly efficient carbide grades: IC5600, designed for machining steel (ISO P group), and IC716, specifically tailored for cutting titanium. Additionally, the insert range has been expanded with new cutting geometries. This includes inserts with a high positive chipformer for milling titanium, chip-splitting cutting edges for productive roughing and other designs. Furthermore, the range now includes inserts with reinforced cutting edges for high feed milling of hard materials up to HRC 60 hardness (ISO H group, Fig. 4).

These new products are also part of ISCAR\\u2019s HELIALU family, which consists of milling tools with parallelogram-shaped inserts for machining aluminium alloys (ISO N group). The expansion of this family includes indexable endmill heads with threaded adaptations for both MULTI-MASTER and FLEXFIT systems providing the option for HPC. The screw-in design configuration of the heads significantly enhances the customisation capabilities of HELIALU tools, allowing for a wide range of MULTI-MASTER and FLEXFIT shanks, adaptors, extensions and reducers to be utilised. Therefore, the development of the \\u2018helical parallelogram\\u2019 has not ceased, and the traditional HELIMILL continues to gain momentum. This development follows a gradual upward helix, revisiting past turns but at a more advanced stage, much like in dialectics.

Listed in: Business

Guhring builds lifelong relationship based on results

LMS Precision Engineering has trusted its tooling supplier for over 35 years. With a relationship that dates back more than three decades, many manufacturers would ask \\u2018why?\\u2019 The simple answer lies in the fact that Midlands-based LMS works with Guhring UK, one the world\\u2019s leading manufacturers of cutting tools with UK manufacturing facilities and expert engineers on hand to deliver optimal machining solutions, whatever the challenge.

Scott Street, a partner at Droitwich-based LMS Precision Engineering says: \\u201cWe are a family-run business that has been operating for over 40 years. Our main sectors of interest are aerospace and general subcontract machining. We have always had a great relationship with Guhring.\\u201d

Discussing the relationship, Chris Bush from Guhring says: \\u201cLMS and Guhring have been working together for over 35 years now. LMS use the whole spectrum of our cutting tools, whether that\\u2019s milling cutters, drills, taps or thread mills. In fact, everything through to the Tool Management vending machine. LMS were one of the first customers to see the advantages of a tool management vending machine. Allowing them to put their resources in providing components rather than manually ordering tools, looking for tools and managing tool stocks. The TM machine automated all this and much more. The relationship has evolved so much over the years. In that period, cutting tool technology has changed and evolved hugely, as has the LMS business, the technology it invests in and the size of the company. The customer base at LMS has evolved as well, and they are machining a lot of different materials, so down the 35-year relationship - it has been exponential growth and change on both sides. However one thing remains, and that is the strength of our partnership.\\u201d

The Guhring Tool Management vending solutions can be built to a customer\\u2019s requirements and are available in open drawer type for maximum versatility or 100% secure single tool dispensing.\\xa0 The system will control and monitor tool consumption and spending with reporting for complete visibility. The main benefits of the Guhring Tool Management vending solutions include 24/7 controlled tool availability and prevention of production stoppages due to tool availability. It will also eliminate loss and theft, create employee awareness of tooling costs and the system can communicate with customer IT systems.

Recalling specific product lines that have supported LMS Precision, Scott continues: \\u201cWe had a lot of joy with the Guhring VA Series drill and now there is the new InoxPro drill as well, so this is bringing us even greater runtimes than ever before. We use Guhring on everything, from end mills such as the high-speed rippers, the through coolant drills, high-speed steel drills, stub drills - absolutely everything.\\u201d

Adding to this, Guhring\\u2019s Chris Bush says: \\u201cLMS use a complete range of our tools and they machine so many different types of material, they have to have material specific cutters as well as general-purpose cutters. They use the whole spectrum of our tooling range. With the range of stainless steel that LMS machines have; the new InoxPro is perfect for them. The Inox Pro introduces a new grade of carbide, so it is a much tougher carbide with a new geometry that is specifically for titanium and stainless steel. We also have the new Perrox coating on there as well. This is a much tougher wearing coating that is a lot smoother and this delivers optimum swarf evacuation.\\u201d

\\u201cThe benefit of using Guhring as a supplier is that we manufacture our carbide. We can make our own grades for specific applications, so we have made tougher grades of carbide that are not as brittle as carbides from other manufacturers. This makes it perfect for challenging applications in titanium and stainless steel.\\u201d

Alluding to the application of the latest generation of tools, Scott comments: \\u201cThe latest tools have given us the confidence to run lights-out, reducing the number of tools we need to stock and giving us full visibility of all tool usage and tool performance. This is especially the case with the VA Series drill. With that drill, we can now run over 1200 parts over a period of 15 hours on 316 stainless, drilling a 10mm diameter hole at 17.65mm deep with no problems at all. It\\u2019s absolutely great. The confidence it has given us is incredible. We have worked with Guhring for 35 years, and the products and support are great. The relationship we have and the products are brilliant.\\u201d

Concluding on the partnership, Chris Bush continues: \\u201cWe have built a brilliant relationship and we are looking forward to the next 35 years. LMS have got exciting new projects coming through and new machines that they are investing in. Combining their technology and the advancement of materials, there will be plenty of exciting new challenges ahead and we relish the opportunity to deliver results long into the future.\\u201d

Listed in: Business

Green light for Nissan's ambition 2030

Nissan\\u2019s devotion to electrification and manufacturing in Britain, is compelling. Huge recent investments underline the company\\u2019s green plans and long-term future in the UK. Will domestic suppliers benefit as the switch over to electric bites and new, high-volume components are needed? By Will Stirling

It\\u2019s June 2016 and the EU Referendum result is in. Shock: the British public voted to leave the European Union. Pandemonium ensues. Prime Minister David Cameron resigns. The cost of exports to the EU will certainly rise. A business story sharp in the memory was Nissan\\u2019s then Chief Executive, Carlos Ghosn, warning that the carmaker could stop investing in its Sunderland plant if EU export tariffs were imposed once the UK left the bloc. New PM Theresa May made a famous deal with Nissan to neutralise the effect of Brexit on its trading conditions. But for a moment, Nissan \\u2013 with the UK\\u2019s biggest car plant \\u2013 had a public wobble about its future here.

Fast forward to March 2024 and things could not be more different.

Carmakers are seemingly vying to be the greenest on the market, but Nissan\\u2019s net zero plan is surely hard to beat. Last November, Nissan heavily ramped up its EV36zero strategy, a roadmap to electrification that it had launched in 2021. The roll call of investments was eye-catching. The company will build three fully electric models at its Sunderland plant as part of a new \\xa32bn investment, which is on top of the \\xa31bn it had already committed under EV36zero to create an electric vehicle (EV) hub.\\xa0

More battery gigafactories are planned; with AESC Envision\\u2019s original battery plant, there will be a total of three gigafactories in Sunderland by 2030. \\u201cThere will also be a renewable energy microgrid, that will deliver 100% clean electricity for both Nissan and the suppliers around the plant, further action to accelerate that journey to carbon-neutral manufacturing,\\u201d said a press spokesperson for Nissan Motor Manufacturing UK. The third gigafactory will be needed to supply the expanded Sunderland plant and may have the capacity to sell batteries to other OEMs. Prime Minister Rishi Sunak said of the investment: \\u201cThis venture will no doubt secure Sunderland\\u2019s future as the UK\\u2019s Silicon Valley for electric vehicle innovation and manufacturing.\\u201d

Many UK customers know the Leaf, the first mainstream electric car to be built in the UK, and for EVs, Nissan also produces the Ariya and the Townstar small electric van. More than one million Nissan EVs have been sold to date, and more than one-third of their batteries were manufactured at the AESC Envision plant, in Sunderland. The \\u2018Nissan Ambition 2030\\u2019 strategy\\u2019s aim is that all passenger car sales will be EVs in Europe by 2030.

As well as the multiple carbon-cutting projects in Sunderland, where over 6,000 people are employed, Nissan recently unveiled three new head-turning concept electric vehicles (not for manufacture in the UK): Nissan Hyper Urban, Hyper Punk, and Nissan Chill-Out. The job of these futuristic concept cars is to inspire take-up of the new production EV models. In fact, Chill-Out will be the design for the next-gen Nissan Leaf.

At the launch event on 24 November 2023, Nissan\\u2019s global president and CEO Makoto Uchida, said: \\u201cExciting electric vehicles are at the heart of our plans to achieve carbon neutrality. It means our UK team will be designing, engineering and manufacturing the vehicles of the future, driving us towards an all-electric future for Nissan in Europe.\\u201d

As a nod to the prevalence of greenwashing, Uchida-san spoke of \\u2018Nissan Ambition 2030\\u2019 being not a slogan, but a reality. \\u201cWe have a vision of exciting electric vehicles, a vision where your car can help your community manage energy, a vision where Nissan becomes a truly sustainable company, where our actions have a positive impact on the environment.\\u201d

In addition to the late 2023 investment, the UK government awarded \\xa315m of funding for a \\xa330m collaborative project led by Nissan to support its carbon-cutting programme.

e-POWER offers a hybrid solution

And it\\u2019s not all about pure electric, as hybrid vehicles have proved popular while EV price tags remain high. Seen as Nissan\\u2019s answer to mild hybrid, e-POWER is its unique electric-drive powertrain that integrates a petrol engine that generates electricity, and a motor that transfers the power. Since its debut in September 2022, more than 100,000 vehicles powered by Nissan\\u2019s e-POWER have been delivered. e-POWER utilises motor control technology cultivated in past EV development activities, powertrain integration technology and energy management technology. By changing the combination of electric-drive motors and power-generation engines, it delivers quiet driving with excellent response over a wide range of vehicles from compact cars to minivans and SUVs.

Manufacturing and supply chains

By investing in three new all-electric models and the total \\xa33bn now being invested in EV36zero; jobs and prosperity from Nissan Sunderland are assured for decades to come.

The batteries, the most substantial component in an EV by value, will be supplied by Nissan\\u2019s gigafactories. Britain needs more battery capacity to satisfy future production. As part of the three new EVs announcement, Nissan said it had initiated a feasibility study to explore potential further gigafactory investments in the UK. Nissan\\u2019s batteries are an NMC design, nickel manganese cobalt, rather than other primary mainstream battery designs like LPF \\u2013 but in fact, both are lithium-ion batteries. This could potentially boost demand for UK-sourced lithium, from suppliers like Imerys British Lithium, because from 2027, materials and parts sourced outside the UK and EU will face tariffs under the EU Trade and Cooperation Agreement. A problem for UK and EU battery makers is the rising cost of materials, especially lithium.

\\xa0But these vehicles also need power electronics, motors, inverters, transmission systems, DC converters, charger ports and other electromechanical parts.

Nissan\\u2019s UK business supports hundreds of component suppliers and is hugely valuable to the UK automotive industry, and the economy of the North East. Tier one suppliers such as Adient (seating), Unipres, which make press-formed and hot-pressed automotive components and body mountings are co-located at the Sunderland site. Under the bonnet, however, electric vehicles need different and fewer components. How will the switch to EVs affect Nissan\\u2019s suppliers, which rely on tens of millions of pounds in contracts?

\\u201cOur work on just transitions suggests that workers in the North East are more confident about the transition to making EVs than workers in the West Midlands,\\u201d said Professor David Bailey, Professor of Business Economics at the Birmingham Business School and a senior fellow of the ESRC\\u2019s UK in a Changing Europe programme. \\u201cThe commitment of Nissan to EV production and sourcing locally made batteries is a large part of that, with a benefit to the local supply chain.\\u201d\\xa0

\\xa0\\u201cAnd yet there are still challenges,\\u201d Bailey adds. \\u201cNissan production has picked up from the lows of the Covid pandemic but is still at something like 2/3rds peak production back in 2016. Furthermore, looking forward to the switch to making EVs will need far fewer components than making ICE cars. That will mean fewer jobs in the local supply chain. Diversifying the supply chain will be crucial for maintaining manufacturing capacity and ensuring a just transition.\\u201d

Carmakers compete to be green

As sustainability is a much stronger criterion for consumer purchases now, car companies compete to show their low-carbon, sustainable business credentials. \\xa0In an analysis by information site Eupedia, that averaged the \\u2018green\\u2019 rankings of car and tyre makers by different organisations\\u2019 green monitors, including S&P Global and the Carbon Disclosure Project (CDP), Nissan ranked 9th among 22 car OEMs. It scored 100% on all CDP metrics but scored 70 on the CSRHub, while the top 10 scored from 82 to 95. \\xa0CSRHub provides ratings of Corporate Social Responsibility (CSR) using 12 indicators of employee, environment, community and governance performance. Nissan\\u2019s new Ambition 2030 is likely to pull up these scores when the green and governance actions have had time to bed in.

Certainly, Nissan\\u2019s devotion to green vehicles is a welcome boost to the EV industry, which is suffering. Private sales of EVs have slowed \\u2013 2023 orders were flat in 2022, according to the SMMT, the Society of Motor Manufacturers and Traders. A recent House of Lords Environment and Climate Change Committee report on the EV industry says the UK\\u2019s EV strategy needs a recharge. Some of this is due to a seemingly coordinated anti-EV campaign in the media. Quentin Willson, the former TV motor journalist, writes in Just Auto: \\u201cAnybody remotely involved with EVs, and electrification, will have seen relentless anti-EV narratives in the media over the last two years. Some papers run an anti-EV story every day \\u2013 literally.\\u201d Public opinion and public relations to promote EV\\u2019s benefits both need to move for the important changes happening at Nissan UK and elsewhere to realise their full potential.

Listed in: Business

5 axis makes low cost jobs financially viable

Many prismatic machining contracts are ideally fulfilled on a 5-axis machining centre that enables components to be produced cost effectively. This is because the two rotary axes are able to position the component quickly and automatically in various orientations for milling and drilling without expensive fixtures and multiple set-ups. A problem arises when the components do not command a high selling price, as most 5-axis machines are a considerable investment.

Subcontractor G&J (CNC) Services in Paddock Wood has apparently found a solution - the Leadwell V-30iT 3+2-axis BT40 machining centre from WH-Lead, Towcester. The entry-level price of less than six figures belies the 5-axis machine\\u2019s extensive capabilities. The hourly rate that the subcontractor charges based on the investment allows less complex prismatic components to be produced efficiently at prices that compare favourably with those quoted by competitors in low-wage countries.

The V-30iT has a novel configuration that consists of a 205mm diameter rotary table mounted on a swivelling trunnion driven from one side. It is supported on the other side by a similar unit built into the side of a 450 by 300mm fixed table. It is unusual on a machine that is already inexpensive to find such a major addition. The fixed table can be used to complete a 3-axis operation on a part weighing up to 50kg before it is transferred to the rotary table. By that time, the part must weigh no more than 35kg if it is to undergo machining at up to 45 degrees tilt, or 25kg if the trunnion position is steeper.

The owner of G&J (CNC) Services, Charlie Naismith, is in a good position to comment on the merits of the Taiwanese-built machine compared with more expensive, fully interpolating 5-axis machining centres of German and Japanese origin used at his other four engineering sites in the south-east. The group of companies, CTN Group, boasts around 100 CNC machine tools of which 10 are 5-axis models.

Mr Naismith said: \\u201cDepending on the value of the parts being machined, which is normally down to their complexity and the material used, you have to make sure the figures add up. Much of our throughput is fairly simple 3+2-axis work in mild steel and aluminium that customers will not pay a premium for, so the Leadwell machine is perfect.\\u201d

\\u201cWe use it in 3-axis mode for much of the time, but the 5-axis functionality is there for when we need it, saving costs associated with workholding, handling and work-in-progress. At the same time, it helps with accuracy by being able to access parts with shorter tools and by cutting down on manual refixturing.\\u201d

He also appreciates the ergonomics of the V-30iT, pointing out that the rotary table when flat is at the same level as the fixed table, so there are no clearance issues. The machine is also well specified, with 800mm of X-axis travel, 460 and 387mm travels in Y and Z, roller bearing guideways, a 12,000rpm spindle, a 24-position tool magazine with 1.8 seconds cutter exchange and 48m/min rapids in X and Y, 36m/min in Z.\\xa0

Control is provided by a Fanuc 0i-MF Plus CNC system, although Siemens, Fagor and Heidenhain are optional, as are specification of 4+1 or full 5-axis interpolation. Another benefit of 3+2 CNC apart from the lower cost, according to Mr Naismith, is that engineers in the Paddock Wood factory can step up to 5-axis machining and build a portfolio of new work around the enhanced capability, while taking advantage of the extra 3-axis capacity for regular work.

The first Leadwell machine, which was also G&J (CNC) Services\\u2019 first 5-axis machine, was installed in 2021. Its purchase was prompted by the need to produce a particular agricultural industry component that would not have been feasible to put onto a 3-axis machine.\\xa0

A second, identical machining centre followed a year later to provide extra capacity and equipment redundancy. Both machines were available ex-stock from WH-Lead\\u2019s Towcester showroom and delivered within a fortnight, together with Renishaw tool and workpiece probing, Filtermist extraction and a post processor for the OneCNC CAD/CAM system. WH-Lead\\u2019s customary high level of ongoing after-sales service and support is being provided.

Generally speaking, parts that previously required four or five separate operations are now produced in two, sometimes without leaving the V-30iT if pre-machining is done on one of the tables. A typical component cited by Mr Naismith for a fluid transfer equipment manufacturer is produced in this way, resulting in a 30% shorter floor-to-floor time compared with when it was produced in four operations on different 3-axis machines.\\xa0

A further advantage of the new process route is that operator walk-away intervals are longer, allowing more meaningful work to be performed elsewhere in the factory while machining is in progress. As a result, it is likely tha

Listed in: Business

Making money in your sleep

Recently rising to the eighth largest manufacturing economy in the world, the route to continued ascension for UK manufacturing isn\\u2019t purely down to the well-publicised need for a national manufacturing strategy or government investment \\u2013 a large burden of responsibility has to lie firmly at the feet of manufacturers and their reticence to automate. The International Federation of Robotics (IFR) frequently shines a light on how far the UK is behind other developed nations. The most recent report shows that 71,000 robots were installed in Europe in 2022, the UK accounted for just over 2000 of those installations. As a world leader in automation, MTD Magazine spoke with Leigh Tricklebank, the Sales Director for Western Europe at FASTEMS to find out why automation is still a cultural challenge for UK manufacturers.\\xa0

Ironically, our conversation with Leigh took place in Opmeer at RODIN Machining, a Dutch subcontract manufacturing business that has invested in a FASTEMS solution to manufacture anything from prototypes to low and medium production runs \\u2013 with a high part and complexity mix. Not only were the MTD team astounded and excited by what we witnessed at RODIN, but we were also a little melancholy as to why we rarely see such levels of automation in the UK subcontract supply chain.

Having a conversation with Leigh, he tells MTD magazine: \\u201cIn the UK, there are upward of 5000 subcontract manufacturers using prismatic four and five-axis machine tools and there is an interesting demographic within that. There are small lifestyle businesses through to serious manufacturers making significant investments. All of these businesses have a similar problem, they need to get orders, they need to process the orders, manage the resources and deliver and serve on time. The level of process quality will differ between businesses, but the overall audience of 5000 companies is huge. Some of these businesses will have a perception that FASTEMS is a pallet automation system that can be expensive and is typically the reserve for OEM manufacturers. It\\u2019s painful to hear this in the UK, as these companies really need to look closer at what we do.\\u201d

\\u201cFor example, we have been delivering Auto Load Devices for more than 20 years - only now we are seeing the gradual uptake of this technology in the industry. For the obvious benefits of increasing uptime, safety and consistency while reducing manual intervention. Auto Load Devices are now becoming increasingly important as we cannot find a generation of people that are willing to pick a part up, put it in the machine and hit the green button. It\\u2019s not only a monotonous job, but it\\u2019s a job that people don\\u2019t want. So, as years have gone by this has become more pertinent.\\u201d

\\u201cReshoring work from overseas is a very real opportunity, but volumes are still typically low and complexity has increased tenfold with the need for diversity and JIT manufacturing. Complex parts, processes and problems are all there - but the volumes are low. It\\u2019s difficult for UK manufacturers to hear, but we are not even close to the G20 figures for robots per 10,000 people. Our position is something like the 22nd largest adopter of robotics in Europe - not the world. It is embarrassing. Ultimately, we have to share the word that automation is no longer a future vision - it\\u2019s a reality, and companies like RODIN Machining are embracing that reality. The \\u2018no-go\\u2019s\\u2019 for companies like RODIN was that they did not want manual data entry and manual actions \\u2013 they wanted autonomy and automation. Subcontractors in the UK should be looking at these points and realising that they should be striving for the same goals.\\u201d

\\u201cThere is a myth that FASTEMS is a system only for large companies and OEMs - it really isn\\u2019t true. We have shown that at RODIN Machining. It\\u2019s a start-up company with four guys. If you look at the areas where businesses generally have problems such as labour and skill shortages, we are taking all of these decisions off the shop floor. Businesses generally have problems on the application side of things on the shop floor, less so on the processing side of things like CAD/CAM. It\\u2019s the button pressers on the shop floor that can kill productivity. The challenge for these 5000+ subcontract manufacturers is that they take an order in good faith and calculate the recipe for manufacturing. After winning the order, subcontractors have to transpose that learning from the sales phase into the engineering department - determining what fixtures, tools and machines to use. This is where the challenges arise \\u2013 challenges that FASTEMS can streamline and simplify.\\u201d

Building Strong Strategic Pillars

Looking more directly at the UK subcontract industry and overcoming the challenges, Leigh continues: \\u201cSubcontract manufacturers in the UK have several issues. These will range from not having scalability, struggling to increase profitability, and the inevitable chaos created by people \\u2013 and FASTEMS can fix all of these things. To put it in simplistic terms, we have four pillars of People, Processes, Investment, and Profitability. Some companies can have a fantastic business, but it may be labour-intensive, regardless of having CAD/CAM, an ERP system, tooling and material databases, high-end machine tools and even an FMS. But what these businesses won\\u2019t have is an overriding process that autonomously takes billets from order to invoice and finished part. In the mix of 5,000 subcontract manufacturers adopting 4 and 5-axis machining, there are a lot of lifestyle businesses where owners do not want to be working over weekends or unsociable hours - they want to make money while they sleep. FASTEMS can provide that lifestyle business for UK manufacturers.\\u201d

Joining the conversation, Mikko Tuomaala, the Marketing Director for FASTEMS comments upon the pillar of \\u2018People\\u2019, Mikko adds: \\u201cWhat automation removes from the human is the \\u2018triple D\\u2019 of manufacturing processes \\u2013 Dirty, Dull and Dangerous.\\xa0 Nobody wants to do these jobs, particularly the younger generation. Additionally, if you think of a machine shop and the people that work there, if you don\\u2019t control the process and its intelligence, this will fall upon the staff and it will create a deviation in results. You want your highly skilled staff to intervene in the optimisation of processes and be more engaged in the business, leaving the mundane operations to the automation system. The understanding of the machining process doesn\\u2019t go away, it is just facilitated by the system and optimised by skilled engineers.\\u201d

Alluding to the pillar of \\u2018Processes\\u2019, Mikko says: \\u201cIn UK manufacturing, there are particular islands of manufacturing, so at the beginning, there could be an ERP system or a CRM system - there is a wealth of data and machines that are often sat there doing nothing. To achieve faster throughput and improve costs, deliveries and quality - the process has to be fixed. What FASTEMS does with its MMS is it acts as the nucleus of the ecosystem bringing in the ERP, the MRP, encapsulating the machine tools, the materials and fixtures - it brings together the recipe to bake a great cake. FASTEMS gives customers the facility to control everything from the door where the material arrives to the finished part at the end, and we can visualise it with our situational awareness. We cannot fix bottlenecks, but we can give customers insights into why a bottleneck exists. We can identify what parameters are causing the chaos in a customer\\u2019s system - from this data, great engineers can fix the problems. Our software empowers engineers to identify problems and create solutions. Automation pushes manufacturers to realise what is obvious. The problem is often the process and not the machine tool.\\u201d

Discussing \\u2018Investment\\u2019 on a UK-wide basis, Leigh adds: \\u201cIn the UK, we use terms like \\u2018manufacturing is culturally important\\u2019, but there has been little investment over the last 30 years. How do manufacturers get investment? They either go through the long-winded painful process of obtaining a grant and if that doesn\\u2019t work they get screwed by the bank on loans with personal guarantees against directors. The level of investment in the UK is embarrassing. We have more than 500 installs in Europe from around 200 customers and this is because our customers keep re-investing with us. We have RE Thompson at the RODIN event and they ordered a cell in 2007, a second system in 2008, and another in 2012. We have just won an order for a fourth cell that will keep their business running for the next 20 years. Our biggest customer in the UK is BAE Systems, the F16 should have been decommissioned around 10 years ago, but they have to keep the program running for the next 20 years on machines that are virtually obsolete \\u2013 our FMS is managing that.\\u201d\\xa0

Looking at the pillar of profitability, Leigh continues: \\u201cCompanies like RODIN Machining look at profitability completely differently from manufacturers in the UK. UK manufacturers often value automation as a third of the cost of a machine tool. For example, a company may buy a machine tool for \\xa3500,000 and they will accept that it will run for 12 to 16 hours a day. Then they realise they need lights out machining for the remaining 8 hours - and this is where the valuation of one third comes from. So, they will be prepared to spend \\xa3150,000 on the automation of the machine tool. If a manufacturer buys two machines, they have an automation budget of \\xa3300,000 - we can automate two spindles for this, but it\\u2019s a poor equation. At RODIN, they started the company with four machine tools and spent 1.5 times that on automation \\u2013 and look at what they\\u2019ve achieved. They don\\u2019t care about the capacity of the CAM system, the machines and the people \\u2013 they care about the capacity of the process. They want to create a drumbeat of creating constant cash flow, autonomously with automation, 24/7 and 365. It\\u2019s a completely different way of looking at the same problem. When UK manufacturers look at the problem from a different perspective, they\\u2019ll find the resolution to the issues of People, Processes, Investment, and Profitability through FASTEMS.\\u201d

Targeting the \\u2018Pinch Points\\u2019

Looking at the pinch points for UK manufacturers, Leigh continues: \\u201cWe are intrinsically linked to new machine tools - and we shouldn\\u2019t be. Ideally, I would like FASTEMS to be linked with manufacturers and their existing machine tools. If we are linked with the purchase of new machine tools, we are there like Oliver asking for scraps from the begging bowl. We want to have conversations with manufacturers regarding their business problems, not the component problems. Most manufacturers will have business issues such as being too expensive, not being able to produce parts quickly enough, stock rates and production downtime being too high, unskilled staff and a struggle to meet customer demand. These are the issues that I hear regularly.\\u201d

\\u201cWe are not here to sell machines and robots, we are here to solve business problems. At FASTEMS, we look at how we can set your business up for the next 40 years - we cannot do that by looking at the X, Y, Z and the A, B and C. The punchline is that at FASTEMS, we don\\u2019t sell a product \\u2013 we sell change. When businesses have a goal and a vision, that is where we can help. The attitude across Europe is that \\u2018if we make this investment, we trust that we will achieve things\\u2019. In the UK, the attitude is very much that if we have an order, we have to get it completed by next week - how do we do it and how can we make the part faster? The next step is to run around the machine tool companies and pick a vendor. However, this is often done with no process, no people and no best practice \\u2013 it\\u2019s just compounding the existing problem.\\u201d

\\u201cAlmost all subcontract manufacturers have chaos, we want to have the adult conversations that look beyond the existing project and what manufacturers want to do over the next 5 to 10 years. OEMs do not have this level of chaos, they have strategic thinking that opens the lines of communication with FASTEMS.\\u201d

Adding to this, Mikko says: \\u201cIt is like playing a sport, as you progress throug

Listed in: Business

Innovation never stops

Where Innovation Never Stops! is the slogan that appears on the walls of the production facilities at ISCAR headquarters and has been synonymous with the company for several decades. The Covid-19 pandemic did not interrupt the innovation process, and between 2020-2021 ISCAR introduced the NEOLOGIQ marketing campaign comprised of advanced cutting tools and tooling solutions for modern metalworking.\\xa0

Significant changes in manufacturing, such as intensive digitising, the shift to electric drive in the automotive industry, and growing precise workpiece fabrication, have emerged with new demands for cutting tools. Notwithstanding, the accelerated pace of changes sharpens the demands and requires more ISCAR NEOLOGIQ products that answer to modern-age machining.\\xa0

The CHAM-IQ-DRILL family of assembled drills that mount exchangeable carbide heads, is now upgraded with new heads in the diameter range of 33 to 40mm. These heads can be mounted on any drill possessing the appropriate pocket size. The main feature of the new heads is a multifunctional cutting geometry, which enables effective drilling of various materials such as steel, stainless steel, heat-resistant special alloys, and titanium - assuring hole precision within IT10-IT9 accuracy grades.\\xa0

The ISCAR LOGIQ-3-CHAM is also based on the concept of exchangeable carbide heads with 3 flutes for improved productivity. This is now supplemented by new carbide heads for achieving a nearly flat bottom hole. Flat bottom holes are necessary for screw head sockets, spring seats, washer ports and more. The heads ensure drilling up to an 8XD ratio without a pre-hole. The new design facilitates generating holes with a nearly flat bottom by use of a single pass. The heads are mounted on existing LOGIQ-3-CHAM tools that significantly expand the application range of the family and reduce inventory costs.

So, how do you increase the drilling depth? Use a longer drill?\\xa0

The MODUDRILL family of modular drills with replaceable carbide heads carry indexable inserts and provide an alternative solution. Mounting an exchangeable extension holder on a drill body increases the drilling depth by an additional 200mm when machining holes in a diameter range of 33 to 40mm.

Key aspects in turning

A modular tool concept is the way to reach high versatility. NEOSWISS is a new tool system with quick-change heads that follows this concept. The system is suitable for turning, parting, grooving, and threading applications. By use of a high-clamping-force mechanism, the heads are mounted on a toolholder. The mechanism provides an accurate cutting-edge position each time and utilises high-position repeatability. The system intended mainly for Swiss-type machines enables the removal of heads and replacement inserts within the tight confines of CNC machining centres.

ISCAR has developed a new lever dual lock securing mechanism for improved clamping rigidity intended for ISO turning inserts. The new design, referred to as the\\xa0

The LOGIQ-F-GRIP features a new highly advanced tool family for parting solutions. The central component is a robust tool block that mounts on a 4-pocket adapter. There are cases when the rib, a reinforcement element of the block, interferes and prevents clamping the block on typical turret positions. NEOLOGIQ overcomes this problem by providing additional blocks with the rib placed on the alternative side of the block. The revolutionary LOGIQ-F-GRIP parting system was designed to achieve extra stability and vibration-resistant high-productivity parting and grooving operations. The highly engineered LOGIQFGRIP is an assembled tool block that comprises a durable holder and a high-stiffness quad blade with pockets for mounting inserts.

The NEODO S890 is a family of 90\\xb0 indexable face mills for rough and semi-finishing operations. The mills mount durable square double-sided inserts with 8 cutting edges. NEODO S890 facilitates face and square shoulder milling while providing an additional option for milling close to shoulders where there are workpieces or work holding fixture constraints. ISCAR customers have requested additional corner radii and tool diameters, therefore, this tool family was expanded with additional pressed-to-size inserts with a 0.8 mm corner radius and cutters in diameters 32 and 25mm including endmill design configurations.

Upgrading toolholders

The ISCAR SPINJET family of coolant-driven high-speed compact spindles for small-diameter tools is intended to upgrade existing machines to high-speed performers. It is now supplemented with the Micro 90 intended for miniature rotating tools in milling, drilling, countersinking, thread milling, engraving, chamfering and deburring operations. Micro 90, made of a solid titanium shell and assembled from only six parts, enables rotating velocities that range from 35000 to 53000rpm while the main machine spindle remains idle.

The chuck thickness is a factor that limits the working space of a tool. This factor often causes an increase in the tool overhang to reach a machined surface. A novelty in X-STREAM, a family of thermal shrink toolholders, is a series of slim design chucks to eliminate such a restriction. The new chucks follow ISCAR\\u2019s coolant jet channel technology providing direct coolant supply to the tool cutting edge.

Changes in metalworking technology place new demands on cutting tools. To meet these demands, cutting tool manufacturers develop new pr

Listed in: Business

FGP Turbos through complex work with Mastercam

Made up of three main companies, the FGP Group is a specialist Tier 1 subcontractor that provides services from design and manufacturing to surface coating, heat treatment, assembly, inspection, testing and more. As one of the three companies in the group, FGP Systems Ltd typically produces prismatic components for the aerospace industry - it is here that the company utilises Mastercam CAM software.

Founded more than 45 years ago, the company bought\\xa0 \\xa0 \\xa0 its first 5-axis machine, a DMG MORI DMU 50 eVolution \\xa0 over \\xa0 20 years ago \\u2013 and 3 and 5-axis machining has since become the backbone of the Yeovil-based business. The company produces a vast array of components for aircraft and helicopters such as valve bodies, actuation parts and service components \\u2013 with complex turbines increasingly becoming the mainstay of production on the shop floor.

Simon Griffiths-Hughes from FGP Systems Ltd says: \\u201cIf we look back over 20 years ago, we had to stay competitive and to do that back then, the buzzword was 5-axis machining. We knew that was the future, so we decided to buy our first 5-axis machine. Our work is five-sided prismatic machining and we needed 5-axis machines to accommodate that. Since then, we have taken on more work like turbines - now we do a lot of turbines in various shapes and sizes.\\u201d

Discussing the complexities of machining turbines, Simon continues: \\u201cThe complexity lies within the programming. A turbine, depending on its complexity has main blades and multiple splitter blades. This requires a lot of programming time and you must have safe and repeatable programming and machining strategies. To support what was the new 5-axis investment 20 years ago, we needed a CAM package to support that, and we chose Mastercam. We did our due diligence and went through a couple of CAM providers, but Mastercam were offering the full support we needed for full simultaneous 5-axis machining. We took the plunge straight into full simultaneous 5-axis machining from the off, and Mastercam was able to support us through that period.\\u201d

Alluding to the challenge of taking on both 5-axis machining and a new CAM system, Simon says: \\u201cAt the time, we just had to get on with it, but the support from machine tool provider and Mastercam seemed to work very well - and this has grown with us as we have added to that portfolio of machines. We now have 15 5-axis machines with a total of 63 CNC machines across two sites, business has grown considerably down the years.\\u201d

Looking at how the workload has changed at Somerset-based FGP Systems Ltd, Simon adds: \\u201cIf we look back 10 years ago, a customer came to us with the need to machine turbines of all different sizes and types. This ranged from scroll turbines and progressed to axial fans. The majority of those turbines at the time were cast and we were very keen to go to a billet solution, which makes it easier for us to start the process. The raw material yield from the casting is notoriously bad and if we go to billet form, it is far easier for us to work on that immediately to get a better yield and reduce cycle times. Once we machine the turbines, we can test them on-site with a spin test of over 100,000rpm.\\u201d

For the parts to perform, they have to be manufactured with impeccable precision. As Simon adds: \\u201cTo get these turbines up to speed, they have to be balanced to within micrograms. If you look at a cast variant, it is very difficult and time-consuming to manufacture and balance with precision. The machining strategies we use on our CAM package, enable us to create a machining solution for titanium or aluminium turbines - and then migrate that solution across to the next turbine. The quality of our turbines is a cornerstone of what FGP Systems is about, and the CAM solution and machining strategies help with this.\\u201d

\\u201cSince we on-boarded \\u2018blade expert\\u2019 through Mastercam, that has taken our off-line programming time down from multiple days or even multiple weeks for complex multi-splitter turbines, down to just an afternoon\\u2019s work. It really is that simple to use. What this gives our business is improved turnaround times. The customers are always demanding shorter and shorter lead times. If we can off-line program a turbine in an afternoon rather than a couple of days \\u2013 that is perfect for our business,\\u201d concludes Simon.\\xa0

Listed in: Business

Cutting the chatter

Productive Machines is on a mission to provide a 15-minute turnaround from receiving data on its cloud-based, artificial intelligence platform to delivering a click-and-play machining protocol that enables manufacturers to machine the best part, faster, first time. John Yates talks to the spin-out team whose software-as-a-service is driving step changes in productivity and sustainability.

Walking along the second-floor corridor to the Productive Machines\\u2019 workspace in the AMP Technology Centre, Rotherham, Dr Erdem Ozturk stops to look through the window at the Rolls-Royce Factory of the Future, whose 3,000sq/m of machining workshops were his research and development laboratory for more than a decade.

Erdem led the Advanced Manufacturing Research Centre\\u2019s brilliant Machining Dynamics Technology Group, which grew in the innovation environment enabled by Dr Sam Turner and AMRC co-founder Professor Keith Ridgway which propelled the Factory of the Future to global leader in aerospace milling.

Their success was achieved by adapting and refining the fiendishly complex mathematical models of machining research pioneers like Franz Koenigsberger and Jiri Tlusty whose ideas were turned into game-changing operational manufacturing methods by their former students, and now professors in their own right, Yusuf Altintas, Scott Smith and Tom Delio.

Perhaps the AMRC\\u2019s biggest success came in 2014 when they applied these theoretical models to vibration control, cutting tool design, and residual stress management in a SAMULET project that was to revolutionise the manufacturing of Rolls-Royce aero-engine discs and shaft components.\\xa0

The improvements in quality, alongside the time and cost savings achieved in the manufacture of the fan disc, have become folklore in the AMRC and the close-knit aerospace manufacturing community: a 50% reduction in cycle times and right-first-time production rates rising from 85% to over 99%. Coupled with cost-savings of \\xa3135m, this made UK jet engine production globally competitive, safeguarding 400 high-value-added jobs and unlocking a \\xa3300m investment in a North East plant.

Not content with this success, Erdem and his AMRC team, along with European partners, began harnessing the power of information technology to push the boundaries of the possible, creating state-of-the-art digital twins that combined machine tool dynamics, control loops, tool-path generation and machining processes, to boost productivity, extend tool life and eliminate chatter.

Productive Machines traces its lineage back to this remarkable pedigree. Formed in 2021, shortly before joining an elite group of start-ups on the ATI Boeing Accelerator programme \\u2013 over 200 applicants from 44 countries were whittled down to just ten \\u2013 the business was explicit from the start in its mission to maximise the productivity and sustainability of machine tools.\\xa0

\\u201cWe are using our unique digital twin to simulate millions of combinations of machine settings to arrive at the optimum feed rate and spindle speed settings for a given process before manufacturing. This eliminates chatter vibrations and provides machining optimisation, preventative maintenance and part quality that may not be achieved by a human operator even with years of continuous improvement,\\u201d says Erdem, who now leads a growing international team of machining physics developers and software engineers from their base in the heart of South Yorkshire\\u2019s Advanced Manufacturing Innovation District.

Having raised a cumulative \\xa33m investment, the company launched its Feed Rate Calculator and Spindle Speed Calculator apps in October and November last year respectively. This was followed by an early access programme for a predictive maintenance service for spindle health monitoring in December.\\xa0

In the next few months, they will be launching the fully automated cloud based system that achieves a 15-minute turnaround from receiving data on its artificial intelligence platform to delivering a click-and-play machining protocol that enables manufacturers to machine the best part, faster, first time.

\\u201cWe saw there was a massive opportunity to turn our cutting-edge technology into a simple, straightforward Software as a Service (SaaS) product,\\u201d Erdem adds. \\u201cUsing artificial intelligence and digital twins of the milling process, we can identify vibration-free parameters and automatically personalise the process to eliminate chatter. This opens up a future where cutting optimisation technology is accessible to all, regardless of the scale of operation\\u201d

One early client, Yorkshire headquartered Ficep UK, a leading supplier of structural steel and plate fabrication machine tools, has seen process productivity increase by 110%, with cycle times cut by 53% while reducing the magnitude of vibrations five times.

Other clients report reductions in machining design and set-up times of 20%; cycle times reduced between ten to more than 50%; operational and maintenance costs cut by 25%; and cutting tool costs reduced by 11%\\xa0

An additional benefit of this software-as-a-service is the way it can dramatically reduce manufacturers\\u2019 carbon footprint. \\u201cBy finally solving the age-old and frustrating problem of machine tool chatter, we calculate that our technology could save a staggering 2.5 gigatonnes of carbon dioxide emissions between now and 2050,\\u201d Erdem says. To put this into perspective, 2.5 gigatonnes is equivalent to the UK\\u2019s total carbon emissions - every factory, fire, car, flight and light - for six years.

While work continues in developing and refining the AI platform for launch in the spring, it\\u2019s fascinating to learn that an essential piece of kit in this operation is one of the oldest in the toolbox: the tap test. Used in aerospace engineering since the 1950s, the tap test relies on simple physics: the kinetic impulse of a hammer strike dissipated as vibration and sound.\\xa0

However, where traditional tap testing relied on skilled individuals to interpret the sounds made by the struck object, such as a machine tool, today\\u2019s digital tap tests are much more sophisticated and precise. Instead of transmitting vibration responses to the ear as an acoustic sound wave, a digital tap hammer sends the vibration response as data to a computer for recording and analysis.

Specialist software then calculates the precise frequency response from those vibrations, considering parameters like the frequency, amplitude, and decay rate of the vibrations, and enables an exact analysis of that tool\\u2019s unique characteristics and condition.\\xa0

From its origins, the age-old practice of tap testing has not only endured but has evolved into an even more powerful tool in the era of smart manufacturing, becoming a critical component of quality control, material characterisation, structural health monitoring.

\\u201cDigital tap testing, enhanced by AI, is ushering in a new era of precision and efficiency in manufacturing. It empowers manufacturers to optimise machine tool performance, reduce waste, and enhance product quality. It is democratising condition-monitoring and predictive maintenance, enabling even small-scale operators to benefit from data-driven technologies without costly investments in sensors or infrastructure,\\u201d Erdem added.

Although focused on the future, Erdem is also a keen student of machining history and one of his go-to authors is the American Quaker Frederick Taylor, best known for bringing the \\u2018scientific method\\u2019 to the early factory system making it more efficient and productive.\\xa0

Taylor also wrote a book On the Art of Cutting Metals, published in 1907, which identified \\u201cchatter as the most obscure and delicate of all problems facing the machinist \\u2013 probably no rules or formulae can be devised which will accurately guide the machinist in taking maximum cuts and speeds possible without producing chatter.\\u201d

Erdem smiles and says Taylor was absolutely right. \\u201cThere were no formulae available to predict chatter vibrations until 1954 when Tlusty was able to formulate the absolute stability limit for chip width for turning operations. That meant if the process planner selected a chip width smaller than this limit, the process would be stable and there would not be chatter vibrations irrespective of the spindle speed used.\\u201d

Seventy years on since the formulation of Tlusty\\u2019s law for the identification of chatter stability lobes in turning processes, the Productive Machines team are coming very close to proving Frederick Taylor wrong by accurately guiding the machinist in making maximum cuts and speeds possible without producing chatter for machining processes.\\xa0

That, I suspect, matters as much to this team as turning a profit.\\xa0

It would certainly delight Keith Ridgway: \\u201cIf I were starting the AMRC today, it would not be by constructing a huge machining research facility. It would be by harnessing the power of artificial intelligence, cloud-based data analytics and digital twins. Product

Listed in: Business

Collaborative R&D helps take the weight off civil aerospace

Engineers\\u2019 obsession with weight and strength is reaching new heights in the aerospace sector. A range of technologies are being developed for manufacture, many with research centre support, that are designed to cut weight and carbon in aviation. By Will Stirling

It was a good landing at the end of 2023. Commercial aircraft orders and deliveries are flying high, and up in 2022 by some eye-catching margins. It seems like aerospace production is back to pre-pandemic levels. According to aerospace group ADS, 2,430 total aircraft orders have been placed globally to 6th December, a 43% increase on the same period in 2022. Single aisle aircraft account for just over 80% of orders placed this year, demonstrating the rapid recovery in the domestic and short-haul travel industry post-pandemic.

Airbus had recorded 1,395 net orders (gross orders minus cancellations) by the 30th of November, beating its full year 2022 orders (1,041) by 350 aircraft with a month to go. Deliveries to date are 623, again set to beat FY 2022 deliveries of 663. Boeing booked 114 gross orders in November, taking orders to 1,207 by 13th of December. The US plane-maker has delivered 461 aircraft to date \\u2013 orders and deliveries both up on 2022 numbers. Boeing\\u2019s official backlog goes from 5,239 last month to 5,324 as of November 30th and like Airbus, its single aisle aircraft \\u2013 in particular the 737 family \\u2013 are the most popular type. To show the comparison with Covid and pre-Covid demand, Airbus has not had such a strong order book since 2014 (1590 orders) while in 2020, it received just 373 orders, about one quarter of 2023. The two main primes are chasing a production rate of about 65 aircraft a quarter, in fact Airbus has stated it wants \\u2018rate 75\\u2019 by 2026.

In November the government announced an Advanced Manufacturing Plan with \\xa34.5bn of funding for sectors including automotive and aerospace, for five years starting in 2025 \\u2013 a bit sneaky to project the cash forward, given that a new government will have to honour this future spending pledge.\\xa0 \\xa3975m is earmarked to support the development of energy-efficient and zero-carbon aircraft technology.

Primes and tier ones are straining to develop low carbon technologies in aviation such as lighter but equally strong parts, sustainable aviation fuel, hydrogen, lighter wing skins, 3D printed structural parts. These endeavours are backed by the Aerospace Technology Institute, a government agency that has granted funded \\xa31.9bn to aerospace companies, near-match-funded by industry, which has a new drive to cut carbon in aerospace called Destination Zero \\u2013 see below.

Here are some exciting low carbon programmes and components in 2023.\\xa0

First transatlantic SAF flight\\xa0

On 28th of November, the first flight by a large passenger aircraft powered only by sustainable aviation fuel (SAF) completed a flight from London Heathrow to New York\\u2019s JFK airport. Hailed a success, observers remarked the shortage of SAF supply is a barrier to adoption and more lightweighting and propulsion technology will be needed to hit emissions targets.

50% lighter landing gear

Think of the incredible forces that go into landing gear when aircraft land \\u2013 the huge mass of the plane, hitting hard into the ground at speed. Now remove half the weight in the landing gear. That\\u2019s what TISICS Metal Composites of Farnborough have done \\u2013 in one key component of the gear, to begin with. It uses metal composites, a blend of titanium or aluminium with a ceramic matrix, to remove up to 50% of the weight but retain the component\\u2019s full strength. This year, TISICS won an Aerospace Technology Institute (ATI) award for the product.\\xa0

Part of a project backed by \\xa32.5m in R&D funding from UK Research and Innovation (UKRI) and Innovate UK, in collaboration with Safran Landing Systems, with its UK base in Gloucester, Light Land is the world\\u2019s largest metal composite component for commercial aircraft. Currently, aircraft are made of 50% metal components, but replacing these metal components with TISICS\\u2019s lightweight and high-strength metal composites, aircraft can become lighter and more fuel-efficient.

A TISICS composite part weighing the same as a packet of crisps (36g), will be able to carry an astounding 5,000kg. The metal composites technology, applied to landing gear, claims to reduce carbon emissions by 9m tonnes annually, and save airlines \\xa3650,000 in fuel costs per aircraft per year. TISICS says that by replacing more traditional metal components with metal composites, the aerospace industry can slash carbon while creating 240 UK jobs by 2028.

Wing of Tomorrow\\u2019s 17m wing skin

Since 2018, a team of engineers at the National Composites Centre (NCC) in Bristol have quietly toiled away on a new composites deposition process: a fully automated, wing skin lay-up using novel high-rate deposition technologies. By the end of 2022, they had achieved a world-first, full scale 17 metre integrated wing skin infused in a single step. This is part of Airbus\\u2019s Wing of Tomorrow programme.

Composite materials enable wing components to be fully weight-optimised and produced with heavily reduced or eliminated sub-assembly and post-manufacturing costs. They also enable faster production cycles. The NCC was tasked with developing technologies and processes to produce three, full-scale, wing cover demonstrators.

The new deposition technology was designed to specification and supplied by UK automation integrator Loop Technology with collaboration from G\\xfcdel and Coriolis. It comprises two bridges, weighing 45 tonnes and 24 tonnes, 7m high by 13m wide, running along a 26m track. These bridges position automated end-effectors to enable cutting and deposition of dry fibre materials to high levels of quality and speed.

The automated process begins at a 20-metre table positioned inside the cell where an ultrasonic cutter profiles the carbon fabric to shape. An algorithm then selects the correct end-effector to pick the material up and then lay it onto the tool. Once lay-up of all the plies, processing and integration is complete, the component can then be infused with resin and cured.

For Wing Cover 3, the complete ply stack of dry fibre piece parts \\u2013 approximately 170 individual dry fibre pieces \\u2013 was deposited using the NCC\\u2019s Ultra High-Rate Composite Deposition, with no manual intervention. The real wings that will use this process will be incorporated in the next generation of single aisle aircraft, the timing of which is unknown.

Recyclable fibre tape for more\\xa0sustainable composite manufacturing

The Multipurpose Fibre Reinforced Thermoplastic Tape (FRTT) Development Cell at the University of Sheffield Advanced Manufacturing Research Centre is being funded by a \\xa31.7m grant from the Engineering and Physical Sciences Research Council. Such a material has huge potential. While aircraft are using more composite materials to reduce weight, their recyclability has remained frustratingly low. Sustainable thermoplastic composites are exciting due to their ability to be recycled, re-moulded and reused time and time again \\u2013 once perfected.

\\u201cWith regards to recycling, thermoplastics can be \\u2018remelted and remoulded\\u2019, making it far easier to recycle these materials over thermosets. You usually keep the fibre in the polymer, as it provides the strength,\\u201d said the FRTT cell project lead at the AMRC.

ATI\\u2019s Destination Zero

The ATI launched its Destination Zero programme in 2021 to achieve net zero carbon emissions for commercial aircraft by 2050, supporting the industry in sustainable design, manufacture, assembly and operations of future aircraft. Its three pillars are to focus on developing 1. Overt zero emission flights, using new propulsion like hydrogen, 2. ultra-efficient aviation, using existing engines that are more efficient, such as Rolls-Royce\\u2019s UltraFan engine platform, and 3. enabling technologies, capturing lightweight components etc.

Recently the ATI launched two new programmes, a hydrogen capability network and \\u2013 of special interest to MTD readers \\u2013 a new SME Programme to assist smaller companies \\u2013 see below.

Elsewhere, Airbus has developed and recently manufactured a cryogenic superconducting electric propulsion system purposely built to aerospace specifications, that should transfer more current and therefore power in an electric powertrain. And Rolls-Royce rec

Listed in: Business

Toolmaker dives into cost savings with Guhring

As a family-run business, Canterbury Tools Ltd has been involved in the design and manufacture of press tools since it was established almost 50 years ago. To optimise the production of specialist press tools, the Wallsall subcontract manufacturer utilises wire EDM machines from Sodick, machine tools from Hurco and cutting tools supplied by Birmingham-based Guhring. \\xa0

The West Midlands manufacturer specialises in the production of single operation tools, progression tools, transfer tools, as well as components and assemblies for automated and robotic processes in sectors as diverse as the agricultural and construction industries through to the medical, IT, aerospace and automotive sectors. To retain an industry-leading position, the ISO: 9001 manufacturer is always looking for opportunities to accelerate performance and productivity \\u2013 and it is this determination to succeed that led the company to Guhring.\\xa0

At Canterbury Tools, the company utilises a selection of 3-axis machines from small capacity to 3m bed machines as well as simultaneous 5-axis machining. Discussing the daily operation of the business, Josh Bennett, the Operations Team Leader at Canterbury Tools says: \\u201cWe pride ourselves on manufacturing high-quality press tooling and this includes everything from single operation to progression tools and small fine blanking work to automotive tooling. Press tools can be quite complicated projects, so we use a lot of different machine tools - and as technology has advanced, what was once done on manual machine tools is now moved to CNC machines.\\u201d

The company machines a lot of challenging materials that can rapidly erode tool life and profit margins if the correct tools are not selected. Alluding to this, Josh says: \\u201cWe take massive pride in what we use in terms of cutting tools, as we have to cut very tough material daily. This means the tool life does make a difference. We do not cut materials like your everyday mild steel and aluminium where you can get away with using the same tools for a long time. When you are cutting things like D2 tool steel and running intricate forms with a high material removal rate, you really can burn through tools quite quickly.\\u201d \\xa0

Alluding to how Canterbury Tools founded its relationship with Guhring, Josh continues: \\u201cWe were introduced to Guhring at the MACH 2022 exhibition. We have always prided ourselves on being at the forefront when it comes to cutting tools. It is an ever-evolving industry, so you have to keep up with the technology. When we spoke to Guhring at MACH, they made promises that we have heard from many other cutting tool companies in the past. Guhring told us things like \\u2018We will improve your tool life\\u2019, \\u2018We\\u2019ll cut your tooling costs\\u2019 and \\u2018We\\u2019ll improve your material removal rates\\u2019. At the time, we were in the market to improve upon what we were doing and we thought we were already using very good cutters - but as always, were open to be proven wrong.\\u201d

Proving a Point

Discussing the first tool that Canterbury used from Guhring, Josh continues: \\u201cThe first Guhring tool was the Diver Series of end mills. Guhring told us that it was the ideal tool for our applications and everyday use. We trialled the Guhring Diver against the tools we were using at the time. To our surprise, they annihilated the performance of the apparently high-end tooling that we were using at the time.\\u201d

\\u201cWe found a 3X increase in performance compared to what our existing tools were doing. This was a massive surprise to our management team, the accountants who deal with the daily costs of our business and most importantly to the machinists on the shop floor. The machinists really saw a difference in what they were doing every single day with the new cutting tools. From this point, we took Guhring seriously and really put their tools through some rigorous testing. From the testing, we saw a threefold increase in our tool life when we ran at the same speeds and feeds as our old cutters. With help from Guhring, their Navigator system and their engineers, we honed our skillset and started to use this skill to push the cutters to within an inch of their lives.\\u201d

Commenting on the tooling performance after upskilling the engineers at Canterbury Tools, Josh adds: \\u201cWe wanted to see exactly what we could get out of the Guhring tools. We were increasing our cutting depths and stepovers by 1 to 1.5 times as well as increasing our speeds and feeds while maintaining a much higher tool life than what we were previously getting.\\u201d

Discussing the switch to Guhring, Josh adds: \\u201cBy switching to Guhring, we found a much higher material removal rate and this meant that jobs were on machines for less time. In the world of CNC machining, this is a massive. You always want the job to be \\u2018on and off\\u2019 the machine as quickly as possible. Additionally, not having to change the cutters as often has reduced the downtime incurred by tool changeovers. To remove, reset and replace tools is a process that can take anything from 5 to 15 minutes - the number of these tool changeovers has been drastically reduced. If you have a tool that you expect to change every hour, and then you change to a Guhring tool that gives you four hours of tool life, you have cut out three tool changes in just one job cycle. Additionally, you have slashed your tooling costs.\\u201d

Discussing the service provided by Guhring, Josh says: \\u201cAnother main advantage with Guhring is their next-day delivery. The service is excellent and if we are really stuck, they can often help us with \\u2018same day\\u2019 delivery. Sometimes, we will h

Listed in: Business

Subcontractor gets a grip with ITC

Like any fledgling company, the wind of change can blow qui\\U0001f3a7ckly through a business, and this was certainly the case for Shropshire Precision Engineering (SPE) Ltd. Initially set up as a \\u2018part-time\\u2019 business, it wasn\\u2019t until Technical Director Robin Chisnall joined the Shrewsbury business in 2017 that the company set about upgrading its machine tool and cutting tool technology \\u2013 with XYZ Machine Tools and Industrial Tooling Corporation (ITC) proving the partners of choice.\\xa0

As an engineer who has been in the industry for almost 50 years, Robin sold his previous business for a life of happy retirement back in 2016, but when he got the call from fellow Director and Company Founder Chris Mills only a year later, the love for the industry was too great a pull. Investment in XYZ machines has improved productivity and throughput, but its the reliance upon cutting tools from ITC that has delivered production consistency, impeccable surface finishes, and reduced waste and costs whilst making a major contribution to productivity improvements.

When the ISO: 9001 certified business was founded in 2014, the workload was primarily centred around the automotive industry. Nowadays, 90% of the workload is focused on serving the rapidly growing and high-demand semi-conductor sector. The company provides a complete manufacturing, cleaning, assembly and packaging service as well as testing and production control. As Robin recalls: \\u201cWhen I joined the company, it was primarily using cutting tools from distribution companies. The issue was a several-day lead time for some standard tools with no guaranteed delivery date. We often had to take jobs off machines because we didn\\u2019t have the tools available. Another area of frustration was in the cutting tools themselves. A repeat order for an end mill would sometimes be a different brand, coating or geometry \\u2013 this completely ruined our performance and efficiency. I had worked with ITC in the past and I knew that their service, support and delivery times were second to none. They are also a UK manufacturer that can manufacture special tools as well as standard products. I called the ITC representative and we set about standardising our tool library and consumption.\\u201d

A lot of components produced at SPE are small delicate stainless and inconel parts. To machine these, SPE implements ITCs 5021 Series of long length centre cutting 5-flute end mills with harmonic fluting and the 5041 Series of 5-flute extended reach end mills. As Robin adds: \\u201cInstead of changing between roughing and finishing tools, we trochoidal mill with the ITC 5-flute Cupro coated tools at high speeds and feeds with a low depth of cut. The surface finishes are incredible and the tool life is 50% better than any tools we have used before. We have recently started three new machinists and they are all struggling to comprehend the remarkable tool life we get from the ITC end mills and the reduction in tool changeovers.\\u201d

The tool life is a huge benefit to SPE, as are the improved surface finishes. \\u201cBefore we started using ITC tools, surface finishes were inconsistent and we used to undertake significant hand polishing \\u2013 this is no longer the case. This is saving our company a lot of labour hours every week.\\u201d

From a productivity perspective, the range of ITC trochoidal 5-flute end mills and also the 2152 Series of 2-flute ball nose end mills that are used from 1 to 8mm diameter for steel machining, have improved throughput significantly. As Robin adds: \\u201cAll of our jobs are small volumes, so we can\\u2019t always track cycle times. However, when we first moved cutting tool suppliers, there were several jobs with 20 or 30-minute cycles that were reduced to less than 10 minutes with ITC tools.\\u201d

As well as using a complete array of ITC\\u2019s UK-manufactured cutting tools that range from end mills and drills through to taps and reamers, the Shropshire manufacturer has also invested in BIG KAISER tool holders from ITC.\\xa0

Alluding to this, Robin adds: \\u201cWhen we moved to ITC, we could conduct trochoidal milling at much higher feeds and speeds. However, the increased cutting forces were pulling tools from our milling chucks. To retain and extend these productivity gains, we needed high-quality chucks. We spoke with the ITC engineer and we bought the BIG KAISER Hi-Power BBT milling chuck with dual face and taper contact. The slim-line design gave us the reach we needed and the clamping forces eliminated tool \\u2018pull-out\\u2019. Additionally, the BIG KAISER chucks improved our rigidity and stability, this allowed us to run our ITC tools at even higher speed and feed rates.\\u201d

Alluding to the quality of BIG KAISER toolholding systems, Robin continues: \\u201cWe have a lot of tight tolerance work and one job requires a series of 6mm diameter reamed holes at a 70mm pitch. We would have to do test runs on parts like this to avoid scrap. This deviation was not down to the machine or process reliability \\u2013 but the toolholders. To eradicate this issue, ITC suggested we try the BIG KAISER MEGA New Baby Chuck for drilling and reaming the holes. We trialled a reamer with the new MEGA New Baby Chuck and it was reaming to a concentricity and precision level within 3\\xb5m. The runout of the previous chucks would never have held such tight tolerances.\\u201d

Concluding on the overall service from ITC, Robin says: \\u201cWe have guaranteed next-day delivery on standard products, excellent technical support and an unfathomable diversity of special products. In fact, with every special tool, ITC will create a product code. This means that we can order the specific code and we will get repeat orders of our special tools that are all manufactured in the UK. This consistency is of critical importance to us. Some of our parts have a value that exceeds \\xa312,000 - to scrap one of these parts because of tool \\u2018pull-out\\u2019, or the run-out on a precision feature is outside tolerance due to an inferior collet is not a

Listed in: Business

Starrag HD reduces cycle times by 30%

Now available from Starrag Heckert, the STC1250 HD is the latest addition to the renowned STC Series that has been designed to provide unrivalled economy in the machining of the most demanding aerospace structural parts, multi-blades and casings. For those challenging components with long cycle times, the STC Series provides a whole host of practical options. The latest arrival, the STC1250 HD machining centre provides excellent static and dynamic properties as well as a tried and tested rotatable head, making it the new benchmark for heavy-duty titanium and Inconel machining.

Commenting on the latest addition to the portfolio, Lee Scott from Starrag says: \\u201cThis is a 5-axis machine with a B-axis table that holds the component and an A-axis on the head, you can actually have an A and C-axis head as well. This new HD is predominantly for optimised roughing and high surface generation finishing of exotic materials.\\u201d

Discussing the differences between the new STC1250 HD and its predecessors, Lee adds: \\u201cWhat hasn\\u2019t changed from previous models is the head configuration. The head is very stiff and rigid and it has a compact design with a range of spindles, particularly geared spindles. We have an impressive drive system in the spindle, which is a gear-driven HSK100 unit and we also have a dampening brake, so we can lock the spindle and stop it from swivelling when undertaking very heavy rough machining. This also helps with dampening when machining in 5-axis mode. This provides very efficient heavy-duty machining capability that is perfect for aerospace structural components.\\u201d

Looking specifically at titanium machining, Lee continues: \\u201cIn the UK alone, we have around 30 STC installations, it is a very successful range. What we have seen from customers is a desire to prove the roughing capability of the machine with no compromise on quality and accuracy. That is exactly what we have achieved with the STC1250 HD. This has been achieved by changing the linear rails to a hydrostatic system - do not get that confused with a box-way system. We have an advanced hydrostatic system, which is a box guideway with a continuous oil film between the two metallic parts that never drains away, so you have zero-friction with no \\u2018stick-slip\\u2019.\\u201d

The STC1250 HD offers a 1.25m by 1.25m pallet with a large work envelope for accommodating workpiece loads up to 5,000kg on the pallet. This is complemented by an X, Y and Z-axis travel of 2.2 by 1.5 by 2.1m with a swing diameter of 2.2m. With such a large work envelope, the new features in the STC1250 HD can offer astounding benefits for manufacturers with large parts that may have considerable cycle times. \\xa0

Discussing reports that the new features of the STC1250 HD can reduce cycle times in titanium by more than 30%, Lee adds: \\u201cAt Starrag\\u2019s Aerospace and Turbine Competence Centre in Rorschach, we saw a 63mm deep cut with a porcupine cutter where buckets of swarf continually fall into the base of the machine. Traditionally, what would have been three or four passes with a tool can now be done with a single pass. The machine may draw more power in that single pass, but overall it has a significantly reduced cycle time when compared to the previous method of multiple passes.\\u201d

Highlighting how the hydrostatic system works, Lee adds: \\u201cThere is a lot of oil in the system, but it is all contained in a recyclable system. On large guideways, there is a thin film of oil of 15 to 20\\xb5m. When a large structure moves around, it could theoretically displace the oil. To eliminate this, we have an innovative multi-pocket system that

Listed in: Business

Ready for Lift-off with OPEN MIND

As the name would suggest, Hill Helicopters is a manufacturer of luxury light helicopters. Since its inception, the company has been on a fascinating journey that is seeing the team of 80+ engineers develop and manufacture a complete aircraft from the ground up. To achieve this, the Rugeley manufacturer has enlisted the support of leading manufacturers from the sphere of machine tools, cutting tools and ancillary equipment. When the company needed industry-leading CAD/CAM technology that is trusted by the aerospace industry, it turned to OPEN MIND Technologies and its groundbreaking hyperMILL CAM suite.

Discussing the foundation blocks of the Staffordshire manufacturer, Company Founder, Chairman and Chief Engineer at Hill Helicopters, Dr Jason Hill says: \\u201cHill Helicopters are designers, developers and manufacturers of the HX50 5-seat turbine light helicopter. We are actually bringing light helicopter manufacturing back to the UK for the first time in 50 years. To sell an effective general aviation light helicopter, you really have to match the price point with high-end supercars. To do that, you really can\\u2019t turn to the existing aerospace supply chain. So, we\\u2019ve had to develop a vertically integrated manufacturing strategy where we manufacture everything in-house from scratch.\\u201d

Commenting on how the company has achieved this, Dr Jason Hill adds: \\u201cWe have developed the entire machining capability and the whole composite capability - for a whole aircraft, transmission system and the gas turbine engine. That has been an enormous undertaking. We have a group of technology partners that have essentially helped us to drag ourselves up the learning curve. This has enabled us to physically machine parts, cast parts and make composite components. OPEN MIND Technologies and hyperMILL have been an instrumental knowledge and support partner in enabling us to program and manufacture complex machined components in a wide variety of materials.\\u201d

Discussing the start of the relationship between Hill Helicopters and OPEN MIND Technologies UK, Justin Talboys-Cotton from OPEN MIND Technologies UK says: \\u201cWe were initially invited by Hill Helicopters to look at their compressor wheel, which is effectively an impeller. It was a very challenging component with very small gaps. It was a challenge they gave us, but from that point on, there has been a wide variety of parts the company wants to make. From there, the relationship has grown and as Hill Helicopters have bought more equipment and machine tools, they have increased their usage of hyperMILL. Being invited into Hill helicopters at such an early stage - before machines and programmers were here, it has been really exciting to be part of this helicopter development programme and watching it grow.\\u201d

The company is fast approaching 1,000 sales with 943 aircraft pre-ordered for delivery to 67 countries at present. It is currently looking to invest in a new facility to accommodate its growth, and every month new milestones are being reached in bringing the project to rapid fruition. Hill Helicopters has pioneered a new approach to delivering and supporting safe, exciting luxury private aircraft ownership at an affordable price, calling the new concept \\u2018General Aviation 2.0\\u2019. General Aviation 2.0 (GA 2.0) is what Hill Helicopters calls an \\u2018end-to-end ownership experience\\u2019 that is entirely customer-focused.\\xa0

It begins with a ground-up modern aircraft design while simultaneously meeting or exceeding the latest EASA and FAA airworthiness requirements. Beyond this, GA 2.0 also provides an all-new, safe and fully supported ownership experience. These factors ensure the new aircraft delivers low operating costs and maintains a stable high resale value, making personal helicopter ownership more attainable than ever before. As an aircraft, the Hill GT50 engine is a 400hp unit with a take-off power of 440hp to 10,000ft, a cruise speed of 140kts and a maximum range of 700nm. The company is also manufacturing a commercial variant, the HC50. The differences between the HC50 and HX50 are price, time to market and customer participation in the HX50 manufacture. \\xa0

Commenting upon the current stage of development, Dr Jason Hill says: \\u201cFundamentally, at this stage, our sole objective is to get through the development of parts and sub-systems as fast as possible. Pretty much everything we do on every single machine here is a first-off, a one-off. So, we must manage the risk of programmer error or machine crashes as we are going through these development phases at pace. The Virtual Machine capability within OPEN MIND is absolutely crucial to us being able to do that with minimum risk and the maximum confidence possible - as quickly as possible.\\u201d

Justin Talboys-Cotton from OPEN MIND adds: \\u201cVirtual Machine optimiser on the gantry mill is ensuring that the customer covers things like rewinding automatically. As a programmer, this means you program as normal even though the machine is complex. Having the hyperMILL Digital Twin set up and Optimizer, we automatically ensure the processes are collision-free and it can run within the machining envelope comfortably. I believe the main aim here in regards to being efficient, is managing lots of parts and lots of design changes that are involved with the components passing through the process chain for the first time. hyperMILL is enabling Hill Helicopters to really optimise their programs, first of all as prove-out for \\u2018fit for function\\u2019 but also to make sure the parts are going to be valid for the production environment as well.\\u201d

Adding to this, Dr Jason Hill comments: \\u201cWe program milling and turning with hyperMILL and it is absolutely instrumental for us to be able to rapidly develop literally, hundreds of complex components in a wide variety of materials to extremely tight tolerances.\\u201d

Concluding on the project, Dr Jason Hill says: \\u201cI have been dreaming about making this helicopter since I was a littl

Listed in: Business

Prima Innovations are shear class

In the November issue of MTD magazine, we reported on our visit to the Prima Power factory in Sein\\xe4joki in Western Finland. We toured the manufacturing facility and were absorbed by the efficiency of the plant. In this issue, we take a closer look at the \\u2018Tech Centre\\u2019 \\u2013 the showpiece for the developments coming out of the Scandinavian facility of Prima Power. By Rhys Williams

In 2022, the MTDCNC crew were lucky enough to get an invite to the Prima Power headquarters in Turin. Like the architecture of northern Italy, that facility was incredibly impressive with multi-axis lasers, additive manufacturing and automation. It was truly like nothing we had seen before - that was until we landed in Prima Power\\u2019s Sein\\xe4joki plant in Finland.

In our November issue, we noted how the state-of-the-art 20,000m² Sein\\xe4joki factory was the daily commute for 250 staff while another 150 employees would primarily work remotely from other parts of Finland or serving customers around the globe. The largest department in the Sein\\xe4joki company is production, employing 40% of the total staff (including the installation group and customer training). The second largest department is R&D, pushing the boundaries of product development. The tech centre is the epicentre of that innovation.

As the centrepiece of the state-of-the-art Sein\\xe4joki facility, the 7000m² centre demonstrates a complete armoury of solutions. During our visit, this included the Laser Genius+1530 with the PSR (Picking and Stacking Robot) and the new EBe 2720 servo-electric driven panel bender that demonstrates the company\\u2019s latest API technology. The EBe 2720 panel bender in the facility forms part of a complete PSBB (Punch, Shear, Buffer and Bend) automation solution in the Tech Centre. At one end, this colossus automation system that stretches some 40m, has the Combi Genius CG1530 laser and punching machine that is fed by the Night Train Genius automation system that has more than 60 storage cassettes \\u2013 each able to hold 3 tons of sheet steel.\\xa0

Completely configurable to the demands of the end user, the impressive Night Train has the CG1530 at one end and at the other, a PSBB line including a Shear Brilliance 1530. Sheets fed to the Shear Brilliance 1530 are then transferred to a buffering station where sheets and parts can be removed, added or flipped over for transfer to the final station, the EBe 2720 panel bender. During our visit, the exceptional level of flexibility and automation was demonstrated with a complete kit of parts being manufactured for an office furniture assembly.

Taking a walk around the Tech Centre with Prima Power UK General Manager, Mr Barry Rooney, he showed us the new EBe2720 (Express Bender) servo electric panel bender. The standalone EBe2720 is one of several models that vary to support different sheet dimensions. Capable of loading automatically from the loading table with precut blanks or being connected to a PSBB (Punch, Shear, Buffer and Bend) for complete automation, the EBe2720 has evolved to deliver low running costs, low maintenance requirements and most importantly in today\\u2019s current climate, very low energy consumption.

With the machine having a seamlessly endless number of options to maximise flexibility, the EBe2720 offers a complete array of tooling designs to accommodate complex profiles. Here, the additional tools and bending blades for small and/or special bends allow small parts to be bent and corrected from a sheet with particularly narrow channels. It is here that the Advanced Profile Inspection (API) technology, a relatively new advancement from Prima Power stands above the innovation of its rivals.

Describing the API technology, that is available on a number of the Prima bending machines, Barry Rooney says: \\u201cThe API system is not completely new, but it is well proven. The API system has a light source and a camera, it uses the light source to see the shadow of the part very accurately. It determines from that what the measurement actually is and then corrects the part. It is like a visual recognition where the machine can identify a measurement and apply a correction. When the system applies the correction, it then watches for spring back and other deviations, so it may do two or three corrections before it gets the right angle. Once it has that angle, it knows what the cumulative correction factor is - and it uses a correction factor again for the next bend. So, it may take two or three strikes at the first bend and the intelligent system will then apply the correct K Factor (ratio between material thickness and the neutral fibre axis) to subsequent bends. When it comes to the second bend, the system intelligently knows the K Factor, but still measures the bend. The time it moves on to subsequent bends, the machine intelligently knows exactly what factors to apply. Once this is in place, an operator can set the machine to check every fifth or tenth part, for example, to ensure it is adhering to quality-control factors. Our system is unique, other solutions may use a process that checks the measurements, but these rival systems don\\u2019t learn from the material and processes. We have a patent on this technology, which can measure and correct the part in real-time.\\u201d

Alluding to the UK customer uptake for machines with these new features, Barry says: \\u201cWe have a lot of customers that want the API technology for its automated quality assurance whereas the DNP is a game changer for companies producing small, narrow profiles such as frameworks and edgings alongside other, larger parts. Other features that have been added to the machine are typically generational updates such as the control system and process optimisation.\\u201d

Shear Brilliance

Upstream from the EBe2720, is a buffering in balancing station. Here, parts can be removed, added or flipped over before processing on the EBe2720. This balancing station is necessary for the technical centre, as upstream from the EBe2720 is the Shear Brilliance SB1530 - a punching and shearing machine that can churn through the work with a strike rate of 1300 holes per minute.\\xa0

Launched at the Euroblech exhibition last year, the Shear Brilliance machine in the tech centre has 30 turret stations, 30-tonne punching force and a staggering 210m/min axis speed. As Barry adds: \\u201cBoth the Shear Brilliance and Shear Genius are machines that are so quick, they are typically embedded with our automation solutions. You have to have automation for the high number of parts that can be produced in such a short time - otherwise, customers would be continually loading and unloading material, so the machines are designed and optimised for an automated environment.\\u201d

\\u201cAs our high-performance machine, the Shear Brilliance can punch 1300hpm at a 1mm pitch and has a 30 station turret. This exceeds the 16 and 20 stations on the Shear Genius machines. On 16-station turrets, a large index tool and/or multi-tool can be allocated to each position whereas on the 20-station turret, only every other position can accept an indexable multitool. However, on the 30-station turret on the Shear Brilliance, we do things differently. We have a larger number of stations and every other position will be up to size D indexable multitool and the smaller positions accommodate single tools, however, as with the 20 stations on the other machines, we can put multi-tools in the small positions.\\u201d

\\u201cWe can hit the correct tool as the intelligent RAM will work with the multitool to select the correct punch inside it. The intelligent RAM and an indexing multi-tool will work together to optimise positioning and maximise productivity. A fixed non-indexable station can also accommodate a multitool - you may not be able to turn the tool, but you can turn the RAM and this will select whichever tool it needs. The overriding aim is to create optimal flexibility for all scenarios, thereby eliminating tool changeovers except for sharpening. On many of our competitor\\u2019s machines, they don\\u2019t have this flexibility so they need to frequently change tools. Some machines rely on tool changing, or tool changers to create the capacity - on our machines, the tooling is in the turret at all times and ready for use. This means we can sit with customers and work out what their production requirements will be and set up the turret around the customer.\\u201d

The Brilliance and the downstream EBe2720 are both fed by the Night Train automation system. Discussing this, Barry adds: \\u201cOn the system in our Tech Centre, the Night Train works with our TULUS user interface software and the NC Express CAM software. TULUS is the user interface and office software that comes in many guises, so customers can select production and process monitoring, it can be interfaced to an ERP system via the TULUS office that offers different levels of connectivity. TULUS can work with an ERP system to do all the scheduling and the programming, so when it comes to production - everything has been done and the CAM software has prepared all of the parts and the nests.\\u201d

\\u201cThe Night Train and connected machines interface into that system and it will then know what parts it will produce on specific dates and times. The system can even be set to schedules where it can run filler parts in between production runs to maximise utilisation and minimise scrap. You can literally automate the system to connect to the customers\\u2019 ERP and the CAM software and TULUS can take care of everything from scheduling and nesting to material management, process tracking and production reporting. Furthermore, the Night Train is a storage system - so it can drastically improve factory layout and inventory management. We have one customer that has bought the Shear Genius and he has opted for a tower system, as this will take all of his material off the floor and optimise his floorspace.\\u201d

Set parallel to, and working in conjunction with the Night Train was the Combi Genius 1530. Utilising the same technology as the punching machines in the Prima Power portfolio, the CG1530 incorporates indexable forming, tapping and marking to increase process possibilities. The fully servo-electric machine is equipped with a 3 or 4kW fibre laser head and this enables the CG1530 to utilise the laser to replace conventional slitting tools to increase material yield using common edge lines, or allow more complex geometries to be cut. \\u201cThe Combi Genius is an extremely popular machine due to its flexibility and capability, which is emphasised in the configuration of the tooling turret.\\xa0

Standing alongside the Combi Genius 1530 in Sein\\xe4joki was a 2D Laser Genius LG+1530. We reported on this high-performance 2D fibre laser machine during our visit to Prima Power Turin last year. However, the Laser Genius LG+1530 in Sein\\xe4joki was connected to the latest Picking & Stacking Robot (PSR). As Barry continues: \\u201cThe PSR isn\\u2019t anything new for our company, but the PSR connected to the Laser Genius+ has been newly developed for that machine. Essentially, the materials are sorted and passed through the tower and then out to a station where parts are picked and stacked from laser-cut sheet. What we are doing is taking the cut sheets away from the system. This works outside the laser, so the laser can continue cutting whilst the PSR sorts the components, takes the skeleton sheet back to the tower, and then gets ready for the next sheet. If there is any issue that prevents a part from being lifted from the skeleton, the intelligence of the system sees this as it detects the sheet being lifted with the part. If the part does not separate from the skeleton, the PSR will shake the skeleton to separate the part. After a preset number of attempts, if the part is not separated from the skeleton, the PSR will move on to the next part - but the machine will know that the part has not been cut correctly and it notifies the operator that the part is still in the skeleton.\\u201d

The Future

Looking to the future, Barry says: \\u201cThe current trend in the global marketplace is a scarcity of manpower, skilled manpower is even more scarce. Furthermore, energy and raw material costs are increasing and the quality of the material supply isn\\u2019t necessarily what it used to be. We are incrementally removing the need for highly skilled staff to alleviate our customers of this very real concern. Our full range of integrated solutions optimise processes, automates production

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Offshore subcontractor takes off with Vulcan

Located in Moray, North-East Scotland, an area famous for its Scotch Whisky, Standfast Precision Engineering Ltd provides subcontract manufacturing services that are far more edifying than a tipple. The manufacturer continually invests in machine tools to serve its clients in the offshore and whisky distillery sectors. The latest investment is a Vulcan 710L VMC from the Engineering Technology Group (ETG).\\xa0

Located in Craigellachie where the River Spey meets the River Fiddich, Standfast has continually invested in new technology to enable the production of high quality components. Primarily working with the oil and gas industry, Standfast has witnessed significant growth in recent years as the offshore industry has enjoyed a renaissance. With a facility that incorporates everything from manual and CNC turning, milling and EDM machining, the company is evolving its business assets to satisfy the demands of its clients.\\xa0

The latest acquisition, a Vulcan 710L VMC with a 4th axis Lehmann rotary unit from ETG was purchased to provide additional capacity and increase the throughput of its smaller components. As Company Owner and Director Graham Wilson says: \\u201cWe had a small bed 3-axis machine with a rotary unit, but the compact work area was limited even further by the 4th axis unit. This meant we could only process very small parts or we\\u2019d have to transfer components to our larger bed machines that are dedicated to larger jobs \\u2013 disrupting our workflow and creating capacity issues. We spoke to Ross Milne at ETG\\u2019s Scottish distribution partner RAM Engineering & Tooling and he recommended the Vulcan 710L VMC.\\u201d

\\u201cWe reviewed the market, looking for a machine with a Siemens CNC in a short lead time, as our workload was ramping up and the issue was causing a bottleneck. ETG provided the solution with the Vulcan, and it has been a tremendous asset since it was installed,\\u201d adds Graham.\\xa0

With a limited floor area, the compact Vulcan slotted straight into the shop floor. The outgoing machine only had a worktable of 500mm, which was too small to fit both a 4th axis unit and a vice for 3-axis work. However, the spacious work area of the Vulcan provides a worktable of 760 by 420mm. Commenting upon this, CNC Machinist at Standfast, Mr Scott Coull says: \\u201cWith the space in the Vulcan, we can fit the 4th axis unit and a tailstock to stabilise larger parts.\\u201d

Operating the machine daily, Scott adds: \\u201cWe program parts at the machine and the new Siemens CNC has a large touchscreen interface that improves programming speed by at least 30%. We typically produce batches from 10 to 20 off, so we can program 10 to 20 jobs each week with each program taking from 15 minutes to a couple of hours, so this saving in programming time is significant.\\u201d

Looking at the build quality and performance of the machine, Scott adds: \\u201cThe Vulcan is a more rigid and robust machine than its predecessor and this enables us to undertake heavier cutting conditions. Furthermore, the previous spindle had a maximum speed of 8000rpm and the Vulcan provides 10,000rpm, this significantly improves our productivity.\\u201d\\xa0

The family business owned and run by Graham and his wife Michelle has also witnessed improved surface finishes, product quality and reduced downtime since the acquisition of the Vulcan. Scott adds: \\u201cWhilst the Vulcan has a tool setting probe that eradicates our previous method of using a dial gauge on every new tool that we put in the machine. This can save us a couple of hours of manual tool setting on the machine each week. In addition, the rapid tool changer is at least 50% faster than the previous machine.\\u201d

Concluding on the acquisition, Graham says: \\u201cWe needed a machine with a particular specification for our requirements that was going to deliver reliability and performance. The Vulcan machine from ETG has more capacity, more torque, and a streamlined 4th-axis system and it provides the space for us to machine relatively large parts in either a 3-axis or 4th-axis setup.\\u201d

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