Machinery & Manufacturing | Issue 13 | Jan/Feb 2024

HIGHLIGHTING MACHINE TOOL & MANUFACTURING TECHNOLOGY

ISSUE 13 | JAN/FEB 2024

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Page 3 0 bringing precision cutting tools to new heights

WATCH VIDEO

Lights out machining Productivity after dark Page 34 Exclusive interview Page 12 Don’t let oil mist cloud your health & safety

Level up your machining We discuss ‘ Automation for the nation’ Event Preview: LET’S TALK GRINDING

Page 26

SOFTWARE Formula One feels the ‘Force’

Making advances with ADGRIND

MACH 2024 is now firmly on the horizon!

Page 60

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Contents 7 Thought : The tide is turning A positive start to the year!

Publisher - Laura Crawford laura@machineryandmanufacturing.com Technical Editor - Steed Webzell steed@machineryandmanufacturing.com Circulation Enquiries circulation@machineryandmanufacturing.com Advertising Enquiries hello@machineryandmanufacturing.com Editorial Submissions editorial@machineryandmanufacturing.com Published in an eco-aware format by Engineering Media Ltd The Maidstone Innovation Centre, Gidds Pond Way, Maidstone, Kent ME14 5FY Tel +44 (0)1622 296112 Company Number : 13634129 VAT Registration 397 8226 41 Our registered company address is : 20-22 Wenlock Road, London, N1 7GU In our mission towards carbon neutral, we publish and replant in partnership with:

Catch up

What’s been happening?

Exclusive interview Don’t let oil mist cloud health & safety The People of #UKMFG Lights, camera, action at The Sempre Group Let’s Talk Grinding Making advances with ADGRIND Software Formula One feels the ‘Force’ Level up your machining Automation for the nation Cover spotlight A ‘World of Dreams’ from OSG UK Ltd

Cutting fluids Productivity after dark

Cleaning MECWASH revolutionises productivity Workholding 1st MTA offers new zero-point clamping Welding Westermans granted as the PEI agent Aerospace manufacturing Innovation slashes cycle times Machining focus Super effectiveness for Superalloys Turning technology Numachine turns to Ward CNC

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Sheetmetal iQuoting pays dividends

Investment Foundry casts its net for new opportunities

Welcome... Welcome to issue thirteen of Machinery & Manufacturing magazine. Crafted by our team of dedicated Engineering Media professionals especially for you, the CNC machine tool intensive manufacturing community. We invite you to enjoy this immersive reading experience packed with video and downloads. This is a hybrid magazine, to be read on or alongside your desktop, phone or tablet. I’m a hybrid! How do you use me? Click or scan the play buttons for instant video Click or scan the download buttons for instant brochure downloads, discreetly appearing on your device in a separate file ready for you to simply hit save.

Heat sealing Shaping the future through collaboration

Robotics Let’s shake on it

Show preview It’s MACH season... Events calendar See you there!

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OPTIMISATION

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The tide is turning

A deluge of good news stories indicate an upturn in optimism that looks set to provide a springboard for UK manufacturers in the year ahead. Make UK’s latest ‘Manufacturing – The Facts’ report, for example, revealed that our manufacturing sector has climbed one place to eighth in the world rankings, overtaking a big competitor, France, in the process. Indeed, Make UK’s Q4 2023 Manufacturing Outlook finds that manufacturers are seeing output surge three times faster than orders. The latest balance for output is +20%, up from +3% in Q3 2023. Notably, Q4 was the third quarter in 2023 where output balances were equal to or exceeded +20%, indicating overall industry growth. Our subcontract supply chains are also seeing a significant uptick, evidenced by the latest Contract Manufacturing Index (CMI) from Qimtek. The CMI showed that the UK market for subcontract manufacturing ended 2023 on a strong note, up 105% compared to the previous three months. Overall, the market concluded 7.5% higher than at the end of 2022. Fabrication was the strongest area, up a staggering 160% on the previous quarter and 12% on the previous year. Growth in our machining sector was also significant, up 51% on the previous quarter and 2.4% on 2022. In November we heard that the UK Government is making £4.5bn available for British manufacturing to increase investment in eight sectors across the UK. Funding will be available from 2025 for five years, providing everyone with longer term certainty about investments. With so much positivity, now is the perfect time for manufacturers to invest, with forthcoming exhibitions like Southern Manufacturing (Farnborough, 6-8 February) and MACH (Birmingham NEC, 15-19 April) providing the ideal opportunity to enhance your production capabilities. Machinery & Manufacturing magazine would like to wish you and your businesses a successful and prosperous 2024. Laura Crawford Publisher

Catch up

In a day dedicated to showcasing advancements in cutting tool technology CERATIZIT UK & Ireland Ltd demonstrated the latest machining techniques and highlighted their technology with machining demonstrations running throughout the day, interactive workholding displays and vending machine presentations. The event was hosted with the support of their partners: XYZ Machine Tools Ltd, Yamazaki MAZAK UK Ltd, STAR Micronics GB, SolidCAM UK Ltd, Open Mind, ETL Fluid Experts, Zoller UK and Bott UK. CERATIZIT delivered expertise on all aspects of metal cutting strategies, ranging from performance machining on the latest machine tools, to coolant supply and wear CERATIZIT UK & Ireland Ltd ended the year with successful Technology Day

detection cutting tool technology.

Shaun Thornton, Technical Manager for CERATIZIT UK and Ireland Ltd commented “We couldn’t be more thrilled with how the day went. We saw an amazing turnout, and we are thankful to everyone who travelled to be with us.” www.ceratizit.com

Birmingham engineer seals Royal Approval

A West Midlands engineer, who has put the region on the international

record-breaking £9.3m year, sending millions of precision components to more than 26 countries every week. He is also a passionate ambassador for developing the industry professionals of the future, revolutionising the firm’s apprenticeship scheme, and working with In-Comm Training to launch the UK’s first Precision Toolmaking Academy in late 2022. “I am genuinely shocked to receive this award; you just never expect to be an MBE growing up and certainly not for, in my opinion, just doing my job,” commented Rowan Crozier. www.brandauer.co.uk

manufacturing map, was recognised in the 2024 New Year’s Honours

List. Rowan Crozier, CEO of metal pressing, stamping and tooling specialist Brandauer, has been awarded an MBE for services to manufacturing and enterprise. The engineer has helped steer the Birmingham company through the pandemic and towards a

Machinery & Manufacturing

Catch up

Digital manufacturer Protolabs recently announced that its partner network, Hubs, has rebranded as the Protolabs Network, giving engineers, designers and product developers access to a broad range of manufacturing capabilities from more than 250 suppliers globally under one brand. This enables them to benefit from competitive prices, faster lead times and a unified customer experience. The transition comes three years after Protolabs acquired the Amsterdam-based manufacturing network, which has seen significant annual growth since the 2021 purchase. “This is the future of the industry— manufacturing that is completely tailored Protolabs Network, formerly Hubs An Intelligent Move High Wycombe-based CNC machine tool OEM Hurco Europe has appointed Joshua Adams to cover Midlands alongside Colin Brice, long established as the face of Hurco in the Midlands. Josh brings with him a wealth of relevant experience. Having completed his engineering qualifications at South Staffordshire College, he operated CNC mills and lathes before moving into sales of tooling and machine tools. www.hurco.co.uk

to what customers need, when they need it, and at the price point they want,” said Peter Horowitz, managing director for Protolabs Network. “It’s exciting to be on the frontline witnessing that evolution.” www.hubs.com/protolabs-network In-Comm Training celebrates record year One of the UK’s leading training providers is celebrating a record 2023 after it completed several strategic projects and saw demand for engineering and manufacturing apprenticeships and upskilling courses soar. In-Comm Training, which operates two state-of-the-art Technical Academies in Aldridge and Telford, saw revenue increase by 25% over the last twelve months. This has been driven by the firm’s largest ever cohort intake (nearly 200 apprentices in Autumn) and a significant rise in the number of companies looking to take advantage of modular courses and the managed services offer that navigates management teams through Quality Accreditations and Health and

Safety compliance. in-comm.co.uk

Machinery & Manufacturing

Catch up

NCMT signs distribution agreement with metal 3D manufacturing company

NCMT Limited has signed an exclusive distribution agreement with Tritone Technologies, a global leader in additive manufacturing (AM) technology. Specialising in metal and ceramic applications, Tritone is expanding its presence in the UK and Ireland through this partnership, which enables NCMT to add AM solutions to its conventional machining equipment portfolio. Jonathan Smart, Managing Director of NCMT says, “We are excited to start our partnership with Tritone Technologies, seeing them as the owners of a groundbreaking technology poised to influence the AM market in the coming years. “As a company renowned for its commitment to innovation and cutting-edge technology, NCMT regards this strategic move as positioning

it at the forefront of industrial advancement. We are now entering the AM sector, elevating our capabilities to meet the evolving demands of modern industry.” www.tritoneAM.com

Cheshire experts offer complete tool investigation service

diagnose and maximise the performance of micro and precision cutting tools. Commenting on the new investment, Rainford Precision Managing Director, Miles Evans says: “When you are servicing customers with tools below 0.2mm in diameter, diagnosing and optimising tool life and performance is a challenge. The Keyence system will enable us to provide a unique service to our customers within the cutting tool marketplace. We wanted to find a way to enhance our offering to our customers and feel that, by offering this new service and combining it with our niche expertise, it will provide our customers with true benefits.” www.rainfordprecision.com

Rainford Precision has invested in a Keyence digital microscope to provide a complete tool investigation and consultancy service for their customers in the UK and Ireland. The new Keyence VHX-970FN digital microscope will enable Rainford to assist their customers to

Machinery & Manufacturing 10

Catch up

The new Walter Tiger • tec WSM33G grooving grade

® Gold

The WSM33G is Walter’s first PVD grade to be specifically developed for the high loads that occur during grooving operations. The cutting tool material combines third-generation TiAlN with TiSiN to form a multi-layer coating with exceptional hardness and increased toughness. A special post-treatment reduces friction and ensures a smooth surface, thereby optimising chip removal and process reliability. Furthermore, the gold top layer makes it easier for users to Bentley scoops Top Employer status Bentley Motors has achieved recognition as a UK Top Employer by the internationally- acclaimed Top Employers Institute. Bentley is the sole UK car manufacturer to be included in the celebrated list. The luxury marque’s approach to employee wellbeing, values, ethics and integrity was commended by the Institute, alongside Bentley’s focus on sustainability, digitalisation and diversity and inclusion. The award is based upon a comprehensive review of the business which highlighted Bentley’s innovative and compelling approach to its employees’ own ‘Extraordinary Journeys’, as well as Bentley’s own progressive strategic ambitions for the future.

detect wear. Walter uses the new PVD coating on single-edged SX cutting inserts with positive engagement and a self-

clamping system. It can also be applied to indexable inserts from the double-edged DX18 system, where a second prism ensures stability in the insert seat. www.walter-tools.com

Centre for Innovation in Sustainable Design and Manufacturing to open in London Tata Steel has signed a Memorandum of Understanding (MoU) with Imperial College London to set up a Centre for Innovation in Sustainable Design and Manufacturing in London. This Centre will enable the acceleration of technology development and deployment in strategic areas, attract talent, and strengthen the industry- academia collaborative eco-system. To pursue this goal, Tata Steel will invest £10 million over four years in this Centre. The Centre will initially focus on four primary themes: manufacturing for the future economy, smart manufacturing, sustainable multi-material joining technologies, and net-zero construction technologies.

Machinery & Manufacturing 11

Exclusive interview

Don’t let oil mist cloud health & safety

Filtermist CEO James Stansfield tells Technical Editor Steed Webzell about why machine shops should take heed of the HSE’s current campaign on metalworking fluids.

As part of a targeted campaign, the HSE (Health and Safety Executive) is warning businesses to make sure their staff are safe when working with metalworking fluids. HSE inspections are revealing poor performance around the control of metalworking fluids and coolants in businesses that use CNC machine tools. To stay on the right side of the law, oil mist extraction specialist Filtermist says machines shops need to implement suitable control measures. Today’s modern machine shops typically use four basic types of metalworking fluids: straight oils, also known as ‘cutting’ or ‘neat’ oils; soluble

Machinery & Manufacturing 12

Exclusive interview

bronchial tubes and lungs retain particles between these sizes, potentially causing a variety of health hazards. Indeed, inhaling the mist generated by machining can lead to lung diseases such as occupational asthma and occupational hypersensitivity pneumonitis (also known as extrinsic allergic alveolitis). Aside from the health issues, oil mist is flammable, accelerating the potential for disaster in the event of a fire. Oil mist also presents a slip hazard and can cause problems with sensitive electrical equipment if ingress occurs - issues that can lead to costly machine downtime and repairs. “Sadly, oil mist is a long-standing problem in machine shops that remains commonplace to this day,” reports James Stansfield, CEO of Filtermist, a company where he has been championing the merits of oil mist extraction for the past 25 years. “We’re still getting large, multiple orders for entire machine shops with no extraction.”

“Although we try to simplify mist extraction for our customers, these systems require correct specification. It’s not just a case of buying a product off-the-shelf and fitting it yourself”

ALARP Although there is no defined maximum

oils; semi-synthetic fluids; and synthetic fluids. While each has its own specific properties there is a common denominator – all generate airborne mist particles. Oil mist is a danger to health and hence requires control within the workplace, enforceable by Control of Substances Hazardous to Health (COSHH) Regulations. Sizing up the issue Oil mist particles which are larger than 3.5 microns separate in the nose and throat, while particles smaller than 1 micron are absorbed into the bloodstream. Unfortunately, the throat,

workplace exposure limit for oil mist, COSHH requires employers to reduce exposure to oil mist particles to ‘as low as reasonably practicable’: ALARP. There is a logical approach to the thought process here. Firstly, is it possible to eliminate metalworking fluids? If yes, great, but if not, it becomes necessary to implement appropriate controls. “The burden of proof is on manufacturers, who must prove they did everything possible to remove the risk,” he explains. “There’s still a lack

13 Machinery & Manufacturing

Exclusive interview

of education in the market. Some think if they can’t see a mist cloud they don’t have a problem, but certain mist is almost invisible to the human eye. It comes in different particle sizes and volumes.” According to Filtermist, machine tool manufacturers and their dealers are stepping up on this issue by recognising the requirement and taking responsibility. The company works very closely with machine tool suppliers, while also serving machine shops directly through retrofit applications. “The latter business area is particularly busy at present because of the HSE campaign,” says James Stansfield. “We can usually offer machine shops an instant price to supply and install oil mist extraction as we have a huge database of machine tools. As part of HSE requirements, extraction requires fitting, commissioning and testing by a qualified engineer. If customers prefer, we have experienced engineers who can visit to perform spot tests and see what mist

level is present. Where there is exposure to mist, it’s a legal requirement to carry out health surveillance even when preventative controls are in place. Businesses will need to involve an occupational health professional and workers should be encouraged to report any health symptoms that occur.” Clean air solutions There are three main types of oil mist extraction system, all of which are available from Filtermist. First are centrifugal units that spin the oil out using centrifugal force. Here, a perforated drum with special vanes rotates at high speed. The unit draws oil mist inside where it impacts on the vanes at high velocity. Drum pads assist the coalescing process and filter out stray particles. Centrifugal force pushes oil to the unit’s outer case where it drains back to the machine for re- use or collection, with clean air returned to the workshop through the top of the unit. The second option is static media solutions

Machinery & Manufacturing 14

Exclusive interview

that soak up the mist, ranging from basic units to high-end Absolent systems which include self-draining filter cassettes (no drain facility means the user does not need to constantly change filters). In principle, the unit draws air inside, with heavier particles falling to the bottom before being pumped out for collection or re-use. Polluted air then travels up through the first filter cassette which traps smaller particles. It’s possible to include a further filtration process, including HEPA filters, in particularly demanding applications. And finally, electrostatic precipitation is another method used for removing oil mist particles. Electrostatic precipitators use an ioniser that produces an electrostatic charge which collects and traps air pollutants on an internal baffle plate. This type of filter is very effective for applications with fine particles. “Although we try to simplify mist extraction for our customers, these systems require correct specification,” says James Stansfield. “It’s not just a case of buying a product off-the-shelf and fitting it yourself. HSE guidance says such equipment requires fitting and commissioning by a competent LEV (local exhaust ventilation) installer. Machine shops need to get it right because we know for a fact that the HSE is

actively knocking on doors as we speak.” The HSE’s unannounced inspections look at how employers are ensuring the protection of workers from exposure to mist generated by CNC machines (see HSE guidance note HSG258 ‘Controlling airborne contaminants at work’). Any failures could lead to prosecution or liability to enforcement action. It could also expose the business to civil claims from employees or invalidate insurance claims. However, above all else, there is of course a moral obligation to protect employees. The fight goes on Despite stricter regulations than ever before, thousands of workers in the UK still contract occupational lung and other diseases, including cancer, each year. Some of these cases are attributable to exposure to dangerous levels of oil mist at work. “We can help put this worry to bed by assessing the risk and deciding what precautions are necessary to prevent or adequately control exposure to oil mist,” concludes James Stansfield. “If required, we can also monitor the situation and maintain the systems accordingly.” n

www.filtermist.co.uk

15 Machinery & Manufacturing

People of #UKMFG

Graduating in digital film production, Chloe Reynolds could probably not foresee a successful career in the manufacturing industry. She tells Machinery & Manufacturing about her remarkable journey in the new series ‘People of #UKMFG’. Lights, camera, action Chloe Reynolds, The Sempre Group

Studying digital film production at university seems a long way from where Chloe Reynolds is now, but in reality there are similarities with her current role as a Product Specialist at precision engineering and metrology specialist, The Sempre Group. “The Sempre Group completely supports my career progression. I feel really valued here: I’m even ‘Star of the Month’ in our latest newsletter.” “It might seem completely unrelated to anything I do today, but I love film and always say it’s about life skills,” she says. “At university I was writing scripts, editing, building a story and pitching film ideas. It loosely translates because today I tell a narrative that conveys a product to generate excitement among adopters.” Post-university, Chloe found herself in a role that later was to prove highly useful: selling energy contracts. “It wasn’t much fun but it was a good introduction to sales. I learnt how to get through to people, how to sell and how to close. We had very demanding KPIs, which has certainly helped me understand the pressures of production personnel meeting targets.” In 2016 she had an interview with The Sempre Group, then Metrology Direct, where everything clicked into place, albeit with some

fast learning. “I was the company’s first foray into business development and I discovered that my phone skills would come in really handy.” Chloe soon became The Sempre Group’s Head of Business Development with responsibility for a team of four. However, now in her early 30s and recently returned from maternity leave, she has seen her business development role evolve. “Today I work directly with our area sales managers to help maintain customer relationships and move things forward quicker. It’s far more than just business development now.” Chloe’s focus area is continuous improvement, backed up by training in lean manufacturing (Lean Six Sigma Green Belt) and 5S. Among her product responsibilities is Arkite, an innovative operator guidance platform that projects real-time work instructions in front of operators to help increase the efficiency while reducing human error and training time. “The Sempre Group completely supports my career progression. I feel really valued here: I’m even ‘Star of the Month’ in our latest newsletter.” From screen star to lean star, it seems. n www.thesempregroup.com/automation- integration/arkite-operator-guidance-system

Machinery & Manufacturing 16

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Lets talk: Grinding

Technical Editor Steed Webzell chats with Peter Harding, Managing Director of Advanced Grinding Supplies, about his journey from apprentice to prominent grinding equipment specialist Making advances

The name says it all: Advanced Grinding Supplies, perhaps better known as ADGRIND. Grinding is an advanced process where expert advice and knowledge is paramount to project success. Few probably know more about this innovative machining process than Peter Harding, the company’s Managing Director, who has grown ADGRIND over the past two decades to become one of the sector’s most recognisable names in grinding technology. At the heart of ADGRIND’s offer is its Swiss-built Studer range of cylindrical (external, internal, universal) high-specification CNC grinding machines. Originally the exclusive

agent for the Southwest of England and South Wales, the arrangement extended to cover the whole of southern UK around four years ago. “Studer machines are suitable for a multitude of industries, including medical, aerospace, automotive, mould and die, and many more,” says Peter Harding. “We have a large aerospace supply chain in the Southwest. However, because we now supply the whole of southern UK, we’ve added many motorsport companies

Machinery & Manufacturing 18

Lets talk: Grinding

– both OEMs and subcontractors – to our customer list. They want machines that can grind triangular shapes, tapered polygons and non- round parts to the highest of accuracies.” Sold on success Among the most recent Studer grinder sales include two machines for a manufacturer of truck starter motors and another for an air bearing manufacturer. Plenty of subcontractors are also prominent among recent orders, including T&G Engineering of West Byfleet, where a new Studer S31 adds to a long list of Studer machine on site. The S31, with its two external grinding wheels and single internal grinding spindle, can undertake universal grinding operations, including high-speed form (non-round) grinding and thread grinding. The S31 also has a HF dressing spindle for dressing the latest in CBN and diamond super abrasives. A further recent ADGRIND sale was a Studer favoritCNC universal cylindrical grinding machine to Dorking-based Tenon Engineering, and another Studer favorit to a manufacturer of garden machinery. “The favoritCNC is very popular: we have aerospace companies using these machines to grind tolerances of ±2µm on parts for products such as engine fuel flow meters,” says Peter Harding. Time to accessorize Of course, there is far more to ADGRIND than Studer grinding machines. The company is also the exclusive UK-wide agent/distributor for vitrified CBN and diamond abrasives, live and dead centres, diamond dressing tools and dressing discs, face drivers, precision tooling, and consumables. Oftentimes the company supplies its customers with complete turnkey grinding packages, providing yet another driver of recent business growth. The past 3-4 years have proved

particularly busy. “Business exploded during the pandemic,” he explains. “All of sudden we had many customers involved in the Ventilator Challenge who needed products instantly. As we hold good stock levels, some customers were even driving to our industrial unit in Gloucester to collect equipment and tooling.” “Business exploded during the pandemic. All of sudden we had many customers involved in the Ventilator Challenge who needed products instantly.” Around the same time, ADGRIND picked up a number of exclusive UK agency deals, including Meister Abrasives, Alfons Schmeier Abrasives, Karl Brukner (centres and face drivers), and another Swiss grinding machine manufacturer: Technica, a builder of centre grinding machines. “Many in the industry still do not realise we are the exclusive agent for these brands as they have long associations with previous representatives,” says Peter Harding. “However, word is slowly spreading and the addition of these products to our portfolio had led to more

Machinery & Manufacturing 19

Lets talk: Grinding

customers and revenue. Due to such a rapid rise in business activity we‘re currently looking to grow our headcount further.” In the beginning Peter Harding’s career story is one of both enterprise and circumstance. He began his engineering journey as an apprentice at Dowty Rotol (now Safran Landing Systems) in Staverton, Gloucestershire. However, the 1980s was a turbulent time with many companies making redundancies. Although he completed his apprenticeship at Dowty, he learnt there would be no subsequent job offer. As luck would have it, Lucas EUI Systems was constructing a new manufacturing plant at nearby Stonehouse, a project that involved the establishment of a new grinding section featuring many Studer machines. “I got a job in the new grinding section at Lucas,” he says. “I was lucky enough to get repeat trips to Studer’s headquarters in Switzerland to learn the machines inside out.” Studer comes calling Then, fate would intervene once more. Sufficiently impressed with Peter Harding, Studer offered him a job as a UK service engineer for Studer grinding machines. He accepted. Six years later, thinking it was maybe time for another change, Studer changed his mind about leaving by offering him the Studer sales agency for Southwest England and South Wales. “I had no experience in sales or running my own business, but I said yes anyway,” he explains. “I’d just spent six years as a service engineer for Studer, so I already knew the customers, and they knew me. I’ve always had a personal approach, which helps build working relationships.” Peter Harding launched ADGRIND in 2002. Knowing that he would not be selling a

new Studer machine every week, he started expanding the company’s offer by meeting customer requests for associated equipment like dressing tools, centres and more. In fact, he soon began working with a UK company that manufactures dressing tools to ADGRIND designs, an arrangement that remains in place to this day. The company also commenced the stocking of coolant filter media. Another initiative was selling grinding wheels, with ADGRIND soon establishing a close working relationship with Saint-Gobain Abrasives. Today, the company holds stock of Saint-Gobain brands such as Norton and Flexovit and, such is the relationship between the companies that Saint-Gobain even adds the ADGRIND brand to certain wheels. “It’s yet another string to our bow,” says Peter Harding. “Many Saint-Gobain wheels are high-end; for grinding materials such as Inconel or tungsten carbide. It gives our customers more options. Many times we not only specify the grinding machine but also the tooling, whether it be bonded abrasives, our own dressing tools, a coolant system, filter media, centres, bespoke tooling, whatever. Ensuring the optimal solution for our customers is a paramount factor behind the success of this business. Looking ahead, the addition of exclusive agencies for Meister, Schmeier, Karl Brukner and Technica, makes me very excited for the future of ADGRIND.” n

www.adgrind.co.uk

Machinery & Manufacturing 20

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Formula One feels the ‘Force’ Software

Mercedes-AMG PETRONAS Formula One Team, a user of VERICUT verification, simulation and optimisation software from CGTech for over two decades, recently completed trials of VERICUT Force™ with highly impressive results.

Machinery & Manufacturing 22

Software

VERICUT Force is physics-based software that analyses and optimises cutting conditions to deliver significant time savings and improved tool life. The trial use of Force on a complex radiator component at Mercedes-AMG PETRONAS Formula One Team provided notable cycle time savings of 25% at the first attempt. The success of Force emanates from its ability to set the maximum reliable feed rate for a particular cutting condition based on four factors: load on the cutting edge, spindle power, maximum chip thickness and maximum allowable feed. With the Machine Shop at the Brackley headquarters of Mercedes-AMG PETRONAS Formula One Team keen to discover what advantages VERICUT Force could deliver, CGTech granted the use of three temporary licences for trial purposes. “We’ve been intrigued by Force since it launched a few years back,” says Robert Brown, Machine Shop Manager at Mercedes-AMG PETRONAS Formula One Team.” The opportunity to run a trial was too good to turn down. It gave us the chance to have a really good look at the software; take the covers off, so to speak.” The trial An actual radiator assembly component from the race car was the perfect candidate for the trial. While highly complex in terms of features

“At the start of the project we had one day of VERICUT FORCE training for our Production Engineering Group here at Brackley,” explains James Peddle, Production Engineer at Mercedes- AMG PETRONAS Formula One Team. “We found it quite easy to use; it has a similar layout to the interface of other VERICUT products. After the training, CGTech gave us six weeks to ‘play’ with the software, applying optimisation to our trial part. CGTech returned at the end of the process to validate our work before transfer to the machine.” The result Machining the Force-optimised part produced outstanding results. The original cycle time was 3 hours and 15 minutes; post-trial it was just 2 hours and 27 minutes. Not only did the Machine Shop achieved this 25% cycle time reduction at the first attempt, but the trial involved the optimisation of just four roughing tools (two- and three-flute end mills). There is clear potential for even further gains. “Theoretically, we could save even more time with some tweaks to entry and exit distances, and feed rates,” says Mr Peddle. “We could have pushed the tools even harder in some areas,

(requiring around 30 tools), the part is small enough to have a relatively short cycle time so the Machine Shop could quickly implement program changes as part of an iterative improvement process. The plan was to produce the part from solid 6000-series aluminium alloy bar on a Mazak Integrex five- axis turn-mill machine. Component tolerances are in the realm of ±7.5 µm. There are also several features with true positions of 0.10 mm, tied up to multiple datums.

23 Machinery & Manufacturing

Software

although we would probably need a machine with different kinematics as the test part was quite small.” The Mercedes-AMG PETRONAS Formula One Team confirms that the 25% cycle- time saving for the test part would translate financially, effectively reducing the cost for spindle time by the same percentage. With costs for labour, raw materials and energy currently very high, reducing component cycle times is today more important than ever. The potential “The ability to machine 10 parts in a day instead of eight, for example, would be huge for us,” states Mr Brown. “Moreover, if we scale-up the savings achieved on the trial part to some of our large components with long cycle times, the savings would escalate dramatically. One of our longest-running parts requires 125 hours. Based on the trial, we could likely save around 30-40 hours on this component by using Force. That’s a lot of extra capacity and cost savings.” Force calculates optimal feed rates by analysing factors that include tool geometry and parameters, material characteristics and cutting material, detailed cutting edge geometry and VERICUT Smart Part Technology. The software

calculates cutting conditions using specific material characteristics, taking into account the strength of the material and the effects of friction and temperature. However, Force is about far more than cycle time savings alone. Cut-by-cut analysis of the interaction between the tool edge and workpiece material means the software is adept at predicting tool wear, delivering significant tool life gains in many applications. “Although the trial part was aluminium, we machine around 25-30% of our components from titanium,” says Mr Peddle. “Using Force on these parts would likely extend tool life and generate savings.” VERICUT Force offers a number of key tools that help visualise and identify areas with the biggest opportunity for savings in both cycle time and tool wear. Force graphs, for example, help users see cutting conditions, excessive forces, machining rates, power/torque, chip strength, material removal, tool deflections, and feeds for the original and optimised programs. Mr Brown has the final word: “Although the use of VERICUT Force is just a trial at present, it’s in our mind. We see it as a highly effective production engineering tool.” n

cgtech.com

Machinery & Manufacturing 24

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MAPAL is a global technical solution provider that produces high-precision cutting tools. In many years of close collaboration with its customers, we have obtained a deep understanding of manufacturing and machining processes to support sectors such as Die & Mould, Automotive, Aerospace, Fluid Power, Energy and Medical. Our two UK manufacturing facilities ensure local expertise is on hand to support customer requirements throughout the UK and Ireland, offering special application-specific solutions as well as a full comprehensive standard tooling portfolio.

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Level up your machining

Automation for the nation

In an exclusive conversation with Machinery & Manufacturing, Phil Cattaneo, Business Development Manager - Automation at NCMT, explains why it’s never too late (or soon) to automate machining

Think again Despite the UK’s automation gap, NCMT is beginning to see a shift. More

When it comes to automation, it’s no secret that the UK lags behind a number of its major European peers, including Germany, Italy and France. The question is, why? Phil Cattaneo, Business Development Manager - Automation at NCMT, has his own theory. “The UK CNC machining sector is very reactive in the way it purchases and plans for new investments, which means automation doesn’t always appear as a viable option,” he says. “In addition, the UK’s approach to subcontracting is somewhat different to elsewhere in the world. In mainland Europe, many will specialise, not just on a vertical market like aerospace, but on specific components within that sector, such as fuel injection parts, wing-frame components or turbine blades. They want to be best-in-class at subcontracting in that particular discipline and are able to develop dedicated processes, including automation, to help them excel. As a result, they can plan their future investments with more certainty.” UK subcontractors are seemingly more varied in comparison, typically spanning a number of vertical markets. Subcontractors want stock machines that are sufficiently flexible to produce any kind of part, making automation more challenging.

machine tool enquiries, from both OEMs and subcontractors, now involve automation. “It’s encouraging to see,” states Phil Cattaneo. “That said, a lot of enquiries which initially include automation turn into orders that only include the machine, with customers planning to add automation later. But there’s a problem with that approach: they start running their new machine and subsequently decide they are too busy to stop and retrofit automation.” Any machine shop in this situation is missing out. Automation can enhance productivity

Machinery & Manufacturing 26

Automation

returns when the batch is complete, unloads the fixtures and loads the next parts.” If the component is not particularly complex, then a gantry loader is more efficient and user- friendly than a six-axis robot arm, he suggests. “Another advantage is that the gantry arm can remain within the work area during machining. This provides the machine shop with an option for running the 2nd Op of the part on the sub-spindle, while the gantry arm is inside changing the part over. The result is reduced cycle time as there is no opening or closing of the door and waiting for a robot arm to enter and exit.” An integrated (on-machine) robot arm such as the Okuma ROID series becomes attractive for parts such as detailed castings or components with difficult edges, and sometimes when the machine shop needs more flexibility or undertakes tasks like in-process inspection. Machine-integrated robots avoid the large footprint associated with robotic cells and negate any requirement for dedicated personnel to program the robot’s movement. “We can also source stand-alone robot arms from third-party suppliers, before performing the integration and any necessary customisation in-house,” says Phil Cattaneo. “We sell the

dramatically, providing fast return-on- investment.

“I regularly visit machine shops with say 20 machines, where often only four or five have green lights to indicate they are running. The rest are idle for whatever reason. Achieving 20-25% spindle uptime isn’t making the most of their investments; this is what automation can put right.” But what type of automation? There are so many variants, with selection hinging on the specific application. There are industrial robots, collaborative robots, stacker cranes and more. Moreover, automation is about far more than robot arms. For instance, NCMT can enhance machine tools from its principals, Okuma and Makino, with options that include pallet changers, gantry loaders and fixture-plate handling systems, to list but a few. Pick and choose “If a machine shop needs flexibility for 1-offs and small batches, or the parts are very complex to handle or expensive to fixture, a pallet changer is a good option,” says Phil Cattaneo. “A human still performs the loading, but the company benefits from extensive unmanned running. The operator

27 Machinery & Manufacturing

Level up your machining

“We always provide a consultative approach to arriving at the best outcome for the customer. There are no gaps in our portfolio and we’re not tied to any type of product or brand.”

customer a turnkey package with single-source responsibility from NCMT. This provides additional support, particularly for first-time automation investors.” Leading the line NCMT also offers full production line automation via flexible manufacturing systems (FMS) or transfer line. “We build FMS around subcontractors with repeat orders or OEMs that have a wide variety of regular parts to manufacture,” he explains. “Using an FMS means any part can go anywhere in the system at any time: all stations are available and ready. Software algorithms work out most efficient route.” In contrast, if a customer has a dedicated part to machine in high volume, a transfer line is typically the best option. A transfer line involves a machine tailored to Op 1, another machine tailored to Op 2, and so on. Each machine is a stopping point at which a specific operation takes place, such as machining, deburring, washing or

inspection. Automation connects the machines, with parts on the automation moving one workstation at a time, synchronously. With so many automation options available, the advice of a specialist such as NCMT can clearly prove invaluable when it comes to specifying the optimal solution. “We always provide a consultative approach to arriving at the best outcome for the customer,” says Phil Cattaneo. “There are no gaps in our portfolio and we’re not tied to any type of product or brand. In my opinion it’s never too late, or too soon, to talk about automation. Machine shops planning to add automation in the next two years might think it’s not yet time to contact NCMT. But it is, because it can take time to figure out the actual requirements and devise the optimal solution. The sooner we start the process, the better.” n

www.ncmt.co.uk

Machinery & Manufacturing 28

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Cover spotlight

Have you ever dreamed of soaring among the stars, racing down a track, battling fires, or delving into the intricacies of engineering? OSG UK Ltd has a product for every dream and every industry, bringing precision cutting tools to new heights and making those dreams a reality. World of dreams Pioneering precision for a

Since its inception, OSG Corp has been a trailblazer in transforming the landscape of precision cutting tools, earning a reputable standing in the manufacturing and engineering sectors globally. With a rich history marked by innovation, a steadfast commitment to quality, and an unwavering pursuit of excellence, OSG UK Ltd has become a trusted and recognised name in the UK industry. OSG UK Ltd’s journey began in 1995 when its parent company, OSG Corporation, strategically acquired the esteemed special tap manufacture Norman Taps and Dies Ltd who had been acting as the agents for OSG as UK Agents. Completing the acquisition in 1999, OSG UK Ltd swiftly emerged as a market leader, emphasising the development of robust relationships and a keen understanding of the unique requirements of the UK market. The company’s dedication to providing high-quality

cutting tools and outstanding customer service garnered swift recognition, setting the stage for its continued success. As the demand for precision tooling surged, OSG UK Ltd expanded its operations, establishing its flagship manufacturing site in

Machinery & Manufacturing 30

Cover spotlight

Nuneaton in the Midlands. Over the years, the company has introduced industry leading technologies, from state-of-the-art machines to innovative services and a skilled workforce. This ongoing commitment to innovation has resulted in a diverse range of cutting tools catering to industries such as automotive, aerospace, medical, and beyond. In addition to supplying globally manufactured products, OSG UK boasts its own product line designed specifically for the UK market – HY-PRO. Encompassing carbide round shank tools for Drilling, Milling, and PCD options, the HY-PRO range has flourished since moving to the Nuneaton facility. Affordable and versatile. An added advantage to this offering is that with it been made in the UK tools are easily modifiable for custom requirements and stock delivery is a next day service. Continual additions to the portfolio have expanded the HY-PRO range, now offering solutions for complex

materials like Nichol Chromium, Titanium, and hardened materials. The success of HY-PRO lies in its adaptability, providing an affordable solution for all manufacturing standards, from bespoke projects to large-scale serial production. Its popularity among manufacturers is a testament to OSG UK’s commitment to delivering cutting-edge tools that meet the diverse needs of its customers. As we step into 2024, OSG UK Ltd shows no signs of slowing down. The company plans to continue its trend of expansion, introducing new machinery, bolstering its workforce, and unveiling innovative products, readily sourced, modified and re-purposed all from within their UK site. HY-PRO 24, the latest brochure for the range, includes more options tailored for Non Ferrous and specifically aluminium components 31 Machinery & Manufacturing

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