Machinery & Manufacturing Issue 3 | May/June 2022

ISSUE 3 | MAY/JUNE 2022

The cutting edge of high fidelity

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Rega Research invest in a XYZ 750 LR

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Investment is essential for UK manufacturers’ energy resilience

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SUBCON 2022 Show Preview

EXCLUSIVE INTERVIEW igus: far more than energy chains, cables and bearings

Machinery & Manufacturing

Contents 5 Thought: On inflation Don’t pay the price of low investment

Our Team Editorial Director - Laura Crawford laura@machineryandmanufacturing.com Contributing Editor - Steed Webzell steed@machineryandmanufacturing.com Circulation Enquiries circulation@machineryandmanufacturing.com Advertising Enquiries hello@machineryandmanufacturing.com Editorial Submissions editorial@machineryandmanufacturing.com

Energy Resilience Investment is essential Catch up What’s been happening?

Aerospace : Manufacturing Flexible manufacturing Let’s talk manufacturing igus: more than chains, cables & bearings

Workholding Technology Holding firm

Welcome... Welcome to issue three of the fantastic Machinery & Manufacturing magazine, crafted by engineering media professionals especially for the Machine Tool intensive manufacturing community. With a genuine passion to support the metal working sector in it’s post covid recovery, the time has come for an immersive reader experience to be enjoyed on or alongside your phone or tablet.

Laser Cutting Getting fit for the future

Robotics Making robots agile Cleaning On the right cycle Software Perfecting the process

Published in an eco-aware format by Engineering Media Ltd. Company Number : 13634129 VAT Registration 397 8226 41 Our registered office address is : 20-22 Wenlock Road, London, N1 7GU

Subcontract Manufacturing From Manual to CNC machining

Turning Technology Speed increases capacity

Front Cover Showcase XYZ assists Rega Research

Production Control Powerful data, the driving force Technology: 3D Printing Collaboration develops VLM TM tech

Maidstone Office : +44 (0)1622 296112

Supply Chain Identifying efficiencies EDM Technology Staying on track

In our mission to be carbon neutral, we are in partnership with:

Milling Lucky number 7-teen Event Preview Subcon 2022

Supplier Spotlight Automation doubles turnover

I’m a hybrid! How do you use me?

Aerospace: Machining Solutions Aero Engine production efficiency Comment: Automation Playing the long game Machining Focus: Materials Amorphous innovation

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Metrology Solutions Precision decision

Machinery & Manufacturing

Unless you’ve been living on the moon or are fortunate enough to be extremely wealthy, you’ll have noticed that most things are climbing sharply in price. This inflationary climate is proving extremely challenging, with prices currently rising at 9% a year in the UK - the highest rate for 30 years. The Bank of England has warned that inflation might reach 10% within months. Of course, this all affects businesses just as much as individuals. The CBI said in February that four-fifths of UK firms expected to increase the cost of manufactured goods in the period March-May 2022. The impact of that action further up the manufacturing supply chain is not without its repercussions. Everything from raw materials such as metals and plastics, through to consumable commodities, are on an upward price trajectory, largely because the cost of energy to produce and transport these items is skyrocketing. So, what’s the answer? Well, although interest rate rises will serve to dull the effect of inflation, it will likely take more to bring price rises under full control, particularly in the manufacturing supply chain. Machine shops must therefore try to offset these added costs through in-house efficiencies, which is why investment should continue. Investing in the latest manufacturing technologies - such as machine tools, cutting tools, work- holding equipment and software - will drive up profitability and stand a business in good stead when inflation begins to slow. You’ll find a number of investment stories throughout our current issue that set out the benefits this strategy brings. There are still some great finance deals available, so let’s not let inflation quell the growing investment momentum we’ve all seen in recent months. That would be a very high price to pay. Laura Crawford Editorial Director Don’t pay the price of low investment

Inline and bespoke metrology solutions Mitutoyo is dedicated to providing customers with the ability to have bespoke metrology systems schemed, designed, built, tested, and delivered to solve a particular measurement need that is not completely met by off-the-shelf products. From inline production metrology to custom fixturing and turnkey solutions – Mitutoyo are an ideal partner to meet your exacting quality standards.

Scan the code to discover more about bespoke metrology systems or visit www.mitutoyo.co.uk/bespoke

Catch up

West Midlands Mayor backs Grayson Thermal Systems

KMF invests over £1 million in new machines Precision sheet metal firm KMF has invested over £1 million on two new machines. The Newcastle- under-Lyme company has bought two new laser profiling machines which will increase cutting speeds, reduce operating costs and allow a greater range of materials to be processed www.kmf.co.uk

Sandvik Coromant has appointed Camilla Nevstad Bruzelius as the new Head of Sustainable Business enterprise, Camilla’s principal undertaking will be to create and travel the Sandvik Coromant Sustainable Small business Method. New Head of Sustainable Business

Camilla retains a Master of Rules (LL.M.) in Worldwide Legislation from Lund

College. She has decades of experience from within the Ministry for Foreign Affairs, most recently as Deputy Head of World-wide Agenda Division. www.sandvik.coromant.com

Hundreds of jobs could be created in the West Midlands with zero-emission technology advancements creating global export opportunities for Grayson Thermal Systems. That was the clear message presented to Andy Street, the Mayor of the West Midlands, during a recent visit to the firm’s Tyseley base, with bosses at the 44-year-old firm convinced that the switch to greener transport solutions presents a ‘once in a generation’ opportunity for their British Steel launches recruitment drive

company and the region as a whole. Managing Director Stuart Hateley believes the area’s traditional strengths in innovation and R&D are already paving the way for new contracts across the world and wants the Government to get behind this drive by making sure that all publicly funded projects feature initiatives that ensure UK-produced goods are given a boost. www.graysonts.com operates. And to support its drive to deliver net-zero steel, it’s now looking to recruit the next generation of steelworkers. The company is currently advertising for 30 graduates to join British Steel in September at its locations across the UK. These include opportunities in mechanical engineering and electrical engineering roles while there are also graduate positions in sales and marketing, procurement, technical and manufacturing. They are also looking for 50 new apprentices. The successful applicants will enrol on three-year training programmes for engineering roles and technical positions. www.britishsteel.co.uk

Ceratizit strengthens support with two new recruits Ceratizit UK & Ireland has expanded its applications support team with the appointment of two additional engineers, Stuart Cooke and Stuart Brooks, who will provide support across the Midlands and North west of England. The applications support team works alongside

Ceratizit’s technical sales engineers to provide customers with an extra layer of reassurance with day-to-day machining, technical support and project development activities. With more time available to

them they can work closely with key accounts while also help to develop business within other customers. “The applications team is central to our ongoing strategy of developing our customer support activities, and these two appointments will be followed by further additions during the year,” says Shaun Thornton, Technical Manager, Ceratizit U.K. and Ireland. www.ceratizit.com

The company has pledged to invest in a range of technologies to build a clean, green and sustainable future for British Steel, its thousands of employees and the communities in which it

Machinery & Manufacturing

Catch up

3D laser sensor for measuring high performance tooling

XYZ Machine Tools was understandably happy when in the first six months of its just ended financial year sales totalled £12 million. This figure was seen as encouraging and extremely pleasing. However, better was still to come with the last six-months of the year far outstripping that performance, adding a record breaking £21 million to the turnover, giving a total of £33 million. The challenge now is to maintain this growth and the opening of two brand new showrooms in 2022 will play a role in achieving that! www.xyzmachinetools.com Expansion of sales territories Due to unprecedented growth in sales of Cincom sliding-head and Miyano fixed-head turning centres Citizen Machinery has decided to increase the number of its area sales managers from five to six in order to maintain the high level of customer support for which the supplier is renowned. Consequently, two promotions have been made within the existing business. Simon Fitzpatrick will serve Ireland, Scotland and territories in the north of England, while James Taylor will look after the south-west. Both have excellent technical expertise and product knowledge gained in applications. At the same time, Tony Nolloth has been appointed UK & Ireland Sales Manager to coordinate full-time Record breaking six-months

SECO Tools to host medical event

With collaboration and innovation in mind, the event will focus on precision medical manufacturing excellence, giving attendees the opportunity to watch medical implant machining demonstrations and participate in discussions about the optimized process, as well as attend industry-specific seminars and presentations. To further support medical manufacturers, Seco has launched a selection of technical and educational content dedicated to real-world medical parts, such as the knee and hip implants featured during the Medical ITI events. Visitors to the Seco website will gain insights into the cutting- edge technologies, trends and individuals that are shaping the medical manufacturing industry through podcasts, videos and other content. Seco and partners will host the Medical ITI event virtually from their locations in Germany, the UK and Shanghai, with other markets hosting physical events and gatherings around the world. Medical manufacturers worldwide are encouraged to register and join live or view the event session recordings on demand after the event. The event will take place on Wednesday, May 18, 2022 in German and on Wednesday, June 22, 2022 in English and Mandarin. www.secotools.com

Walter Ewag UK has announced a step change in the fully automatic measurement and digitisation of tools with the launch of the Walter 3D laser sensor that enables the Walter Helicheck Pro and Plus tool measurement machines to scan with four times the resolution than previously possible and to process that data four times faster.Ideal for inspecting high-performance

tools as used in industries including automotive, aerospace and medical where cutting edge geometry, pitch and spiral pitch vary widely, the 3D sensor could replace two separate machines traditionally used for measuring such tools - perhaps a combination of conventional and laser checking. www.walter-machines.com/en

ACCRETECH has announced the launch of the SURFCOM NEX. An evolution of the popular ACCRETECH SURFCOM range, the new measuring system draws on extensive applied experience to consistently meet customer requirements. The cutting-edge SURFCOM NEX allows both surface and contour measurements to be made flexibly and accurately by a single machine. Furthermore, the highly-efficient instrument delivers up to 60 percent faster measurement processes. www.accretech.eu ACCRETECH SURFCOM NEX

the activities of all sales territories. www.citizenmachinery.co.uk

Machinery & Manufacturing

Energy

for UK manufacturers’ energy resilience Investment is essential

Following the publication of the Government’s Energy Strategy, it was subsequently announced by the Department for Business, Energy & Industrial Strategy (BEIS) that the Energy Intensive Industries Compensation Scheme, an initiative that supports major energy consumers with relief for their electricity bills, would be extended until March 2025. The level of support being offered is also expected to increase. With soaring energy costs continuing to impact high energy use businesses, particularly UK manufacturers, Capitas Finance believes that whilst this scheme will provide much needed support for British industry, organisations need to look beyond the next three years and investigate all the ways they can protect themselves from rising costs, including investment in low carbon technology. The company, which has funded energy resilience projects for brands including Rygor (the largest Mercedez Benz commercial dealership in the UK), the Wave and Mole Valley, believes that investing in energy efficiency measures – from replacing outdated lighting to the implementation of large-scale renewable solutions, EV infrastructures and distributed energy schemes – will play a vital role in improving energy resilience and reducing operational costs. With 49% of companies saying it could take over a year for energy prices to settle, Capitas says now is the time to benefit from the savings energy resilience measures can deliver. Such

investments will also help those businesses who have committed to decarbonisation of their operations and aligned themselves with domestic climate reduction targets. We heard from

Revolutionary

Darren Riva, CEO of Capitas Finance “Now is the ideal time for energy intensive business to take action and protect themselves from rising energy costs. This can be achieved by investing in low carbon technologies

new i Groove technology

that reduce energy bills, reduce reliance on the grid and accelerate the pathway to decarbonisation. “We understand that finance could be one of the biggest barriers to positive change, and many businesses will be put off taking the necessary steps that will improve their energy resilience due to a lack of access to investment funds. But it is vital to remember that not every change has to be complex or costly.” “As a specialist energy solutions finance company, we can help remove the barriers to energy finance. We’re here to help these businesses become more resilient, and by working closely with customers we can offer solutions that make it possible them to maintain their operations, reduce their commercial risks, and remain competitive.” n www.capitasfinance.com

Truly revolutionary technology, patented by Sodick

With i Groove, the EDM cutting wire is rotated, so workpieces are machined with a fresh, unused wire surface, ensuring improved surface quality and geometric accuracy, while minimising wire consumption. Just the latest development in Sodick’s three “Concepts of I”: Innovation, Intelligence and Initiative.

Sodick sole UK dealer: Sodi-Tech EDM Ltd., Agincourt Road, Warwick, CV34 6XZ Tel: +44 (0) 1926 695 777 Email: sales@sodi-techedm.co.uk If you want the best EDM technology, with the best service and support – talk to Sodick. www.sodi-techedm.co.uk

Machinery & Manufacturing 11

Let’s talk: Manufacturing

igus ® : far more than energy chains, cables and bearings

Licence to print “We’ve always been active in the field of high-tech engineering plastics, so when 3D printing started to become a production process we began exper- imenting by seeing if we could get our proprietary materials to print,” states Matthew Aldridge, managing director at igus UK Ltd. “We had a great degree of success and a whole range of engineer- ing materials has been developed over the past four or five years that are suitable for 3D printing, using both FDM and SLS processes.” igus has two ways of approaching the market. The company can supply its materials to customers for use in their own printers or, more typically, customers can send a CAD model for printing at igus. Turnaround is 1-3 days to manufacture the parts, plus 24 hours shipping from the company’s advanced 3D printing centre in Cologne, Germany. “We’ve achieved a number of breakthroughs in this area,” says Mr Aldridge. “For instance, we now have an FDA-approved material for use in the food industry. We can also print extremely large parts up to 3m in length.” igus can even print injection mould tools. If a customer has a complex part design and needs to test a prototype, but wants to avoid the considerable cost associated with manufacturing a standard metal production tool, igus can 3D-print a plastic tool set that will be sufficient to mould a few hundred pieces. Notably, 3D printing services from igus are available online. Customers can drag and

Matthew Aldridge, managing director of igus UK Limited, talks with contributing editor Steed Webzell about some of the company’s less familiar but rapidly growing business areas Recording global sales in 2021 of €961 million, igus® is a major supplier of parts for the machine building market, holding more than 234,000 energy chains, cables and plain bearings in stock. The company has around 4500 employees at 31 subsidiaries, backed up by 47 sales partners in a further 52 countries. But today there is far more to this progressive business than meets the eye, with igus providing a comprehensive range of customer solutions in areas such as 3D printing and low-cost automation.

“3D printing is not the answer to every engineering problem, but it is part of the portfolio of solutions that we offer in 2022”

drop their 3D models into a dedicated area on the company’s website. After selecting the material required, users instantly receive a price and, if satisfied, press the order button. This digital provision also includes online service life calculations based on actual wear results measured under laboratory conditions. “UK demand for 3D printing is high,” states Mr Aldridge. “Budgets for components and tools are being squeezed, as are lead-times. 3D printing is not the answer to every engineering problem, but it is part of the portfolio of solutions that we offer in 2022.” Low-cost automation Another interesting and perhaps less familiar aspect of the igus offer is low-cost automation. However, Mr Aldridge explains that this evo- lution of the company’s business was a natural progression. “We manufacture a range of linear bearings – a very special plastic liner held in a housing

that slides on a linear rail made from anodised aluminium,” he says. “Our automation offer grew from there when we then started adding a drive system to those slides, either a lead screw or a belt. We then began adding couplings to the ends, and stepper motors, so we ended up with a complete linear module. By combining a number of modules we found that we could build an entire XYZ Cartesian or gantry robot, something we’ve now been doing for the past 10-15 years.” Using that same idea and core technology, igus can mount its linear slides in different configurations to make delta, SCARA or even a six/seven-axis articulated arm robots, all offering the familiar igus premise: no lubrication, no maintenance, predictable life. The company supplies the robots as assembled units or in component kit form. Igus has invested heavily in developing a control system to run its robots: the igus Robot Control. As a point of note, an online version of the Robot Control software is available for use

Machinery & Manufacturing 13

Machinery & Manufacturing

Let’s talk: Manufacturing

Plastics for motion, not the ocean The plastics used by igus are not for single-use applications, but instead form part of a circular economy that sees the company reuse up to 99% of its plastic waste, reintroducing it to in-house manufacturing processes in granular form. We have ISO14001 accreditation as well as recycling programmes for certain major product groups, such as our e-chain® range of energy chains,” says managing director Matthew Aldridge. “Customers can return their worn energy chains, even those made by competitors, and know that we guarantee to recycle and reuse them in industrial components.” The company has a corporate goal of being carbon neutral by 2025, which is an ambitious target, but igus is implementing many changes within the business to try and meet this aim. “This is not a tick-box or greenwashing exercise, we’re very serious about contributing to a cleaner planet,” says Mr Aldridge. “All that said, some people don’t realise that far less energy is required to manufacture a plastic bearing than a metal one. Plastic bearings are also smaller and weigh less, so there are fewer emissions attributable to transportation. Another key point is that plastic bearings do not require lubrication, unlike metal ones, reducing the potential for environmental contamination and making them a very ecological choice.”

online free-of-charge. “Customers can visit our website and select a delta robot, for example, and use the online Robot Control software to move it on-screen in a way that replicates the actual application,” explains Mr Aldridge. “So when the customer receives the actual robot, they already have the program and simply load it into the Robot Control.” Ample cost savings are available with low-cost automation from igus. For example, a basic SCARA robot will cost as little as £5000, perhaps £7500 after adding an end effector and a controller. In terms of service life, while igus might calculate life as three years, for example, the robot will not fail at that point, it will simply require replacement of its liners. “It’s a very cost-effective option for small factory tasks that require automating,” says Mr Aldridge. “Furthermore, this year we’ll have collaborative robot [cobot] accreditation for one of our models, helping us to enter the market for robots working with human operatives.” He concludes: “With massive pressure on robots globally to help boost productivity and solve labour shortages, low-cost automation is a rapidly growing area of our business.” n www.igus.co.uk

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Machinery & Manufacturing

Aerospace: Manufacturing Solutions

“Thanks to the excellent cooperation between SKF and Fastems, we were able to quickly find new and innovative solutions and reach important milestones in the project”

but recurring quantities over a very long time, SKF Aero had to completely rethink its existing production strategy. This was because until then, a series of manual activities were an everyday part of specific production processes. The task now was to find powerful and precise machinery for the complex production of bearing components and upgrade it with SKF expertise. In addition, the machining – including the necessary auxiliary processes – had to be fully integrated into a single, highly productive solution. “We wanted to automate as many process steps as possible and dramatically minimize manual intervention. That’s why we started looking for partners – both for “Industry 4.0” machinery and for the automation of this ambitious project”, says Jakob.After a thorough review of potential system integrators, SKF Aeroengine ultimately chose Fastems; and for good reasons, as Marcus Jakob reports: “It was important to us that our partner could respond flexibly to the very different requirements of the overall project, which will also be rolled out to other SKF Aero plants, as well as responding to individual requests. The software plays a crucial role in this. Robots are standard today and are easy to acquire. But what’s crucial here are expertise, integration and flexible implementation in the application itself. What impressed us about Fastems was the size of the company, the number of in-house software developers and above all their expertise in flexible software solutions for automation.” The initial ideas from SKF Aeroengine were refined in the course of the project with Fastems

to the present system known as the “RoboFMS” (Robotic Flexible Manufacturing System). “Thanks to the excellent cooperation between SKF and Fastems, we were able to quickly find new and innovative solutions and reach important milestones in the project”, says Jakob. The machines and systems connected to the flexible manufacturing system give an impression of the complexity of the overall solution, consisting of: two turning/milling centers/ grinding center/ lapping machine/ 3D coordinate measuring machine/ parts cleaning system / laser marking system. The RoboFMS also includes a loading and unloading station for automated guided vehicles (AGVs) and a storage unit for blanks, semi-finished parts and finished parts. The RoboFMS links up all the process steps in a single FMS: from the initial machining of the workpieces previously clamped on zero point clamping systems at the loading station to the two turning/milling centers, to processing on the lapping and grinding machine, to laser marking and quality control, taking account of the previous process steps. The robot traveling on a rail is able to handle workpiece pallets as well as workpieces without a pallet. Vandevoir says: “For reasons of precision, the machining processes on the lapping and grinding machine can only be carried out without clamping, so at this point an employee has to unclamp the workpiece at the loading station so that the robot can first load the lapping machine and then the grinding machine with a semi- finished part.” Once the tools have been prepared and

Flexible manufacturing

The production of small batches down to single workpieces is not something generally associated with highly automated systems – especially if the production involves complex machining, with additional, sometimes difficult process steps, and when comprehensive

The company is also the center of excellence for thermal treatment of rolling bearings and roller production in Europe. “About two years ago, we received an order to manufacture special roller bearing components for the new LEAP engine generation, the successor to the CFM56 engine. This order was unique for us in terms of its volume, spanning a period of 20 to 30 years, with individual batch sizes ranging from five to thirty workpieces per job”, explains Cedric Vandevoir, Process Engineering Manager at SKF Aeroengine France. “It is a state-of-the-art turbofan engine manufactured by CFM International using the latest technologies. The machining of the complex, medium-sized rolling bearing components is very demanding, and necessitated new machining strategies and maximum precision to meet the quality requirements,” explains Marcus Jakob, Global Process Development Manager at SKF Aerospace. Given the demands for high-quality, traceable and above all economical production of small

quality control is required. SKF Aeroengine and Fastems have

cooperated to create a solution that is capable of doing just that. The individual handling of workpieces and their pallets is combined in a flexible manufacturing system (FMS). Based in Rouvignies, SKF Aeroengine France is part of SKF Aerospace and is one of five SKF subsidiaries in Europe, specializing in manufacturing bearings for the aerospace industry. With a workforce of 630 employees, SKF Aeroengine makes all kinds of rolling bearings for aircraft and helicopter engines.

Machinery & Manufacturing 17

Machinery & Manufacturing

Aerospace: Manufacturing Solutions

there is enough material in stock, the RoboFMS is designed for a high level of autonomous production over a long period of time. “Our aim is to be able to produce for an entire weekend unmanned, even in batch sizes of 1. The prerequisite for this is that there are enough clamped workpieces and unclamped semi-finished parts in the system storage unit so that all stations in the RoboFMS can be operated at any time. We are currently working on enabling the system to produce all the rolling bearing components in a highly automated process, without manual set-up by operators”, says Jakob. One of the essential components of the project, according to Cédric Vandevoir, is athe FastemsManufacturing Management Software (MMS): “We will soon be connecting the MMS to our ERP system so that we can directly plan production on it. The software will then also control and monitor the entire automated production. The MMS also enables us to map the overall efficiency of the RoboFMS so that we can react quickly when required, for example by specifically optimizing individual processes. The software offers all the prerequisites for this.” The cooperation between SKF Aeroengine and Fastems can already be considered a success, as Vandevoir says: “With the RoboFMS we can

produce even the most sophisticated bearing components in the required quantities and the highest quality, and can thus supply our customers with customized rolling bearings within the agreed deadlines. The automation system makes a key contribution to this. The FMS has become an essential part of our production and therefore our competitiveness and our success. “ Gilles Ofcard, Factory Manager at SKF Aeroengine France, adds: “With this automation project, we are ideally prepared for major changes in our industry. That’s because our sector is characterized by an increasing variety of products with ever smaller production batches. Naturally, some of us have reservations about such changes, which are due to the very high level of technical skills and the requirements for quality and performance in a competitive market. But we cannot resist this fundamental change, which is all the more reason for us to show that the technology helps us to further improve our quality level, to increase our flexibility, to stabilize our processes and to make

our production safer.” n www.fastems.com

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Workholding Technology

excellent holding power whilst only needing to apply minimal clamping forces. The quick loading/ unloading nature of the LANG Technik system means much quicker job change over times. “The need for reduced holding pressure ensures that we are able to hold, from the softest to the hardest of materials, under all machining conditions without fear of component deformation or other damage. Also, as the LANG Technik stamping unit makes its indentations into just the last 3 mm of workpieces, we are now also making savings on material.” The multiple advantages gained from the use of the innovative LANG Technik Pre-stamping technology and Makro Grip Vices has ensured that it has become the benchmark clamping method for ultra-secure 5-axis machining. The toothed jaws of conventional vices must perform two distinct roles, as well as indenting workpiece’s material, they must also securely hold the workpiece under machining loads. Commonly used vices are only able to exert a maximum pressure of approximately 4 - 6 tons, as a result, the effective penetration of their jaws into workpiece material can be problematic, especially when clamping harder metals. The use of LANG’s advanced stamping technology overcomes these issues by applying

up to 20 tons of pressure during the pre- stamping of workpieces. In addition to holding the workpiece in the vice under the most severe machining conditions, the truncated pyramidal shapes of the pre-stamped indents prevent the teeth from impacting deeper into the workpiece by providing a final penetration limit. Despite the application of relatively low clamping pressure, the holding forces exerted on workpieces held in Makro Grip vices actually become greater, the harder and more resistant the material being machined is Complimentary to the efficiency gains delivered by LANG Technik’s advanced stamping technology and Makro Grip Vices, SPE is also benefiting from the use of LANG Technik’s Quick-Point system. Alex Nelson concluded. “In addition to LANG Technik’s workholding products proving ideal for our use, we have received excellent levels of technical help from the staff of LANG Technik UK. We are confident that the additional daily machining time created by the use of our new highly efficient workholding systems will result in a rapid return on our investment and we will soon be returning to the company for additional products.” n www.lang-technik.co.uk

Holding Firm

Swiftool Precision Engineering Ltd (SPE) produces safety critical parts for a global customer base. To ensure that it remains at the forefront of manufacturing technology developments SPE regularly invests in the latest, cutting-edge machine tools. In accordance with the business’s quest for ever higher standards of efficiency and quality, and to enable its advanced machine-tools to achieve their full productive potential, SPE recently invested in a range of innovative workholding devices from Lang Technik UK. Amongst other workholding, SPE ordered LANG Technik’s advanced stamping technology, Makro Grip Vices and the company’s Quick-Point Workholding system.

Project Applications Engineer at Swiftool Precision Engineering, Alex Nelson explained the purchase and use of the company’s efficient new workholding systems. “Amongst other reasons, our continuing growth is driven by strategic investments and by our policy of constantly seeking ever more efficient ways of working. Having invested in expensive, high-yield machine tools we constantly explore ways of maximising their full productive potential. “As our machine tools are usually engaged in high-value, relatively short machining runs, we recently investigated the availability of efficient workholding systems that would help to speed-up our non-productive change-over times and that would increase our productivity levels. Having considered other systems, the ideal answer to our search was found in LANG Technik’s advanced Pre-stamping technology, Makro Grip Vices and the LANG’s Quick-Point system. “By the use of LANG Technik workholding systems on our machine tools we have slashed our job change-over times and achieved the production increases we were looking for. It helps that now, much of the work associated with setting-up the next job due on our machine tools can be carried-out whilst a current job is being machined. “For instance, within the cycle time of a currently running job, we use our new LANG Technik stamping unit to make very accurate, minute indentations into our next to be machined workpiece blank before putting it into one of our LANG Makro-grip vices. As the features on the vice’s jaw precisely engage with the workpiece’s pre-stamped indentations, we can achieve

“By the use of LANG Technik workholding systems on our machine tools we have slashed our job change-over times”

Machinery & Manufacturing 21

Machinery & Manufacturing

Robotics

Fuzzy Logic making robotics agile

MBDA a manufacturer in the aerospace and armaments sector, specializing in the design of missiles and missile systems wanted to robotise certain processes in small series or even single unit production, by allowing an operator with no programming skills to teach the robotic system with just a few seconds for the process to be carried out and executed within the cycle, without human supervision. MBDA France’s Bourges site produces numerous small series of composite parts that have to be moulded. Each mould is manually stripped clean before being used in production. This operation is complex: the parts to be treated are diverse and numerous and in each series, the level of residue to be stripped off, and its location may vary. This method of operation is tedious, and it also requires protecting the operator from exposure to toxic substances. Vincent Rafin, Head of the Factory of the Future Project at MBDA explains: “At MBDA we look for agility when it comes to robotisation. We want to robotise tasks which cause muscolo- skeletal disorders in our operators, and which occur in certain cases in the production of very small series or even single parts, so we need to keep the non-recurring costs of programming as low as possible. Programming a robot to define the trajectories of a laser is not the right approach for

small series production, it is time-consuming and costly and has to be done by a roboticist. For advice, MBDA turned to Meliad, a recognized expert in the aerospace industry for surface preparation and laser stripping, and to Staubli. The latter recommended Fuzzy Logic for its universal, visual programming solutions. Fuzzy Logic developed Repplix™, an extension of its Fuzzy Studio™ software, in cooperation with MBDA. A portable learning device, controlled by the operator using his knowledge of the application task, teaches the Repplix™ software the first laser alignment. A monitoring function, performed via a real-time digital twin of the robotic installation created in Fuzzy Studio™, takes into account collision monitoring and trajectory feasibility in the robot´s environment. Alert parameters are set up. Trajectory capture combines several process parameters such as laser triggering and power. The operator, who is not a roboticist, is also able to modify the

series of moulds.

being used immediately, with no real training required. Our solution allows the robotisation of processes where this has previously been impossible. What´s more, we have barely finished the initial application, and already, Repplix™ is being deployed by other users in Europe.” As Denis Gardin, MBDA’s Director of Innovation and Future Technologies concludes, “This innovation is the achievement the vision of MBDA engineers and operators who, working in close collaboration with innovative SMEs, have succeeded in taking the first step towards implementing a robotic solution which breaks the cost barrier for a wide range of use cases thanks to programming by non-invasive capture of the operators’ know-how.” Although many companies, particularly SMEs, may think that their production presents insurmountable barriers to using automation, modern robots and software are showing that there are no real obstacles and that increasingly, robotic production is for everyone. n www.flr.io

The solution developed in this way, is executed with millimetre precision, and is capable of extension to even more demanding applications in the future. The manual operation can be reproduced with ease because the learning device is the representation of the real tool and is not directly linked to the robot. The operator manages the execution and planning of the movement himself using the software and the parametrized alerts. The time needed to programme the mould cleaning operation is slashed from several hours to only a few minutes. Productivity is increased by automating the cleaning operation and the risks for the operator are reduced. This makes robotising this operation profitable, both in terms of HSE and economics.Ryan Lober, CEO of Fuzzy Logic adds: “With Repplix™, the robot becomes a precision tool in the hands of the operator. Our solution allows him to automate his task in complete autonomy, without any intervention from a specialist. Another advantage is that Repplix™ is designed to start

trajectory and process parameters via the graphical interface, even after the

learning phase, Then, from this digital twin, the cycle is launched and the robot moves with the laser, guided by the accurate capture of the trajectory learned from the operator. The speed at which the robot operates is set directly in the software, it can differ from the speed in the learning phase. The cycle is performed autonomously by the robot, without the need for operator supervision. The same process, which takes only a few minutes, is done for each new

Machinery & Manufacturing 23

Machinery & Manufacturing

Cleaning

removes contaminants, including coolant and swarf, which were traditionally quite challenging. Since using the Solo 600, we have seen a drastic increase in capacity which has improved the efficiency of our process. “The Solo 600 can clean both our large and smaller sized components in any combination of stacked fixtures. Our larger, more awkward fixtures fit easily in the 600x600 opening at the front. A further benefit has been the Health & Safety improvement, with far less lifting required from the team.” The MecWash Aqua-Save system also reduces downtime by continually recycling the wash water to keep it at its optimum condition. It continuously recovers and re-uses the wash water in the parts cleaning system so the need for disposal is significantly reduced. Water quality is maintained throughout production ensuring that parts exit the system in a clean condition, without contamination with oily residues. The only effluent resulting from the Aqua-Save is a concentrated waste, consisting of the oils, emulsions and soluble waste washed from dirty components, which represents typically less than 5% of the total water volume. Brompton’s continual investment in green technology is at the centre of the company’s ethos. John Pattison, managing director at MecWash, said: “We were confident that the Solo parts cleaning system would be a great fit for Brompton. The high cleanliness specifications combined with the requirements for improved speed and efficiency. “They are a fantastic company with a world- renowned brand and have become a standard- bearer for manufacturing in this country. The installation of the Solo 600 at Brompton has helped to create a simple, and effective cleaning process, and to reduce the risk of injury to the staff.” Brompton is Britain’s biggest bicycle

SOLO Parts Washing System

Developed to satisfy the needs of inter- stage, in-cell and in some cases final machined component cleaning to high standards. The Solo parts washing system is supplied in three sizes, all of which provide rotational

right cycle On the

washing, mist rinsing and hot air drying in a very compact footprint, saving on valuable floor space.

The Solo parts washer far outperforms traditional dunk washers, rotary basket and tunnel washers for cleanliness and effective drying. FEATURES & BENEFITS • Effective removal of preservative oils, machining lubricants, metal swarf and chips from machined components • Fully enclosed - no steam and unpleasant vapours • Rotational high volume spray washing, mist rinsing and hot air drying • Very compact footprint, saving valuable floor space • Over 200 Solo parts washers have been supplied to customers around the world

Following significant growth in production at Brompton Bicycles, the company needed a parts washing system that could manage the high-volume cleaning requirement at the factory. Brompton approached MecWash to create a cleaning system that could cope with their specific and rigorous demands, a system that could clean the raw materials before brazing and still be adept at cleaning the finished components machined for the bicycle frame. After consultation with the MecWash team, Brompton ordered the MecWash Solo 600 due to its effectiveness in cleaning preservative oils, machining lubricants, metal swarf and chips from machined components. Christopher Glover, Manufacturing Engineer

at Brompton, comments: “We contacted MecWash as they could create a system that could cope with the requirements at Brompton. “One of the main selling points of the machine was the bespoke main frame fixturing that the design team came up with. It is our largest component which previously had no wash requirement. We then updated our machining processes to increase part quality, but this meant that we would now have to wash our largest component, which the Solo enabled.” Paul Jarratt, sales manager at MecWash, said: “Brompton had specific requirements for their system. The Solo parts washer far outperforms traditional dunk washers, rotary basket, and tunnel washers for cleanliness and effective drying. The powerful rotational washing and hot air drying in a compact footprint provided the cleaning functions that Brompton required.” Christopher Glover continued: “The Solo

Download Brochure

Machinery & Manufacturing 25

Machinery & Manufacturing

Cleaning

manufacturer and have established the company as worldwide leaders in the manufacturing of folding bicycles. In the 1970’s, Brompton founder Andrew Ritchie designed the prototype for his folding bike, and ever since, Brompton has built its reputation around highly engineered folding city bikes that can be carried on to buses and trains. It has become one of the country’s fastest growing manufacturers, a great example of how design and technology-intensive products can be made profitably in the UK and achieve global success, with successful stores in Tokyo and New York. The ambitious and forward-thinking company is set to build a new £100 million (link) factory in the UK, due to open in 2027. Currently, Brompton are based in their West London factory in Greenford, with a welding division in Sheffield. The welding division create the titanium framesets that are welded using TIG in the specialist Sheffield factory. All Brompton core products are built by hand, and are assembled using brazing. Brompton’s’ processes include CNC machining and automatic brazing, as well as the hand brazing that the company is famous for. n www.mecwash.com “The installation of the Solo 600 at Brompton has helped to create a simple, and effective cleaning process, and to reduce the risk of injury to the staff”

Turns your 3-axis vertical machining center into a full 5-axis turning / milling center with Direct Drive up to 5’450 rpm

Fully sealed Super-fast with Direct Drive – up to 5’450 rpm and versatile Accept a large assortment of workholding

Machinery & Manufacturing

sales@uk-pl-lehmann.net 0121 368 0843, service@uk-pl-lehmann.net 07496 330 699, www.lehmann-rotary-tables.com/en

Software in Manufacturing

the process with VERICUT Perfecting

As a manufacturer of CNC machines since 1840, WaldrichSiegen is a prime example of sustainability due to the company’s ability to adapt to changes by investing in new, innovative technologies. Moving from the era of the steam engine to Industry 4.0 the company has maintained its core DNA.

actual manufacturing.

“With VERICUT, machine collisions can be avoided, complex clamping situations can be safely retracted or cycle times can be reduced while at the same time increasing tool life,” says Christian Apel, Sales Representative of CGTech Deutschland GmbH. This is particularly appreciated in large- scale machine tool construction, where process reliability is the be-all and end-all. In order to grasp the significance of error-free machining, it is worth taking a look at the key data of the world’s largest horizontal lathe, built after the customer’s “Go” in 2009 at WaldrichSiegen: 7,000 mm turning diameter, 25,000 mm workpiece length and more than 350 tonnes maximum workpiece weight. Previously, the company produced a lot of waste and had to do endless machining tests. Today, VERICUT makes it possible to safely speed up NC programs, improve part quality and reduce machining times. WaldrichSiegen not only uses VERICUT simulation software to streamline its own manufacturing processes, but that of its customers too. Indeed, the company wants to use digital transformation and its integral elements such as the digital twin in VERICUT, to develop new fields of activity and to transfer real added value to customers. For example, by integrating customers and partners into the company’s value creation processes at an early stage. Timo Hees, Application Technician at WaldrichSiegen, says: “When a customer orders a machine we often carry out studies upstream so that we can

“This makes it possible to make valid business decisions at all levels”

determine and evaluate subsequent machining times at an early stage. “It’s well thought out and well done: WaldrichSiegen simulates the customers machining in VERICUT, to demonstrate the machining and process times for the customer’s parts,

WaldrichSiegen is defined by two words: accuracy and performance. The company specializes in large machine tools and its

customers are mainly manufacturers of heavy marine engines, crankshafts and turbine rotors – who are increasingly demanding. That’s why WaldrichSiegen has invested in future-oriented technologies such as NC simulation with VERICUT to not just meet the needs of its customers, but to surpass them. For them, and its customers, the use of VERICUT software makes it possible to be more efficient and profitable from the start. Since 2009, the company of 350 employees, has been using VERICUT, the industry standard for CNC simulation, G-code verification and optimization. With the production simulation of the NC data, i.e. the machine code, WaldrichSiegen recreates the real machining situation with a “virtual processing machine on the desk”. And this, even before flying the first chip, because VERICUT simulates the original NC G-code after the post-processor is executed in order to detect program errors such as fast- forward errors or contour violations before any

even before the actual machine is installed at the customer’s premises. This makes it possible to make valid business decisions at all levels.” Timo Hees explains: “VERICUT is an integral part of the project. The machine is then made available to the customer with the kinematics developed in collaboration and tested by WaldrichSiegen. This is the only way to ultimately guarantee that all functions can be performed appropriately, so that the customer can already perform their own simulation and check internally in VERICUT if everything is in line with what they had planned.” WaldrichSiegen draws on decades of experience to develop high-performance solutions that are perfectly suited to a wide range of applications. WaldrichSiegen is part

of the HerkulesGroup, which has more than 1500 employees worldwide. A specialist in the development and production of large machine tools, it offers its customers complete high- precision machining to make the most complex parts. Furthermore HerkulesGroup’s companies also offer customers absolute added value with their machines, taking into account life-cycle costs from the moment of construction. Thus, the machines are energy efficient, easy to maintain and repair and are the highest quality down to the smallest detail. n www.cgtech.co.uk

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Machinery & Manufacturing

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