HIGHLIGHTING MACHINE TOOL & MANUFACTURING TECHNOLOGY
ISSUE 11 | SEPT/OCT 2023
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Aerospace manufacturing : Productivity takes off
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Subcontractor exclusive interview : Hidden gem
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Show Preview: LET’S TALK INJECTION MOULDING Advanced Engineering The shape of things to come
TALKING TECH Aerospace tooling special
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Contents 7 Thought : Time to get physical It’s showtime!
Our Team
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
Catch up
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What’s been happening?
Exclusive : Subcontracting We speak with a hidden gem, DK Holdings Let’s Talk Injection Moulding The shape of things to come
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The Career Files Chloe Sales, a bright spark
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Materials Metals sector embraces trading innovation
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Aerospace manufacturing Productivity takes off with Starrag
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Published in an eco-aware format by Engineering Media Ltd.
Aerospace Supplier Brother, a clear choice for aerospace Talking Tech : Aerospace tooling Flying high with MAPAL Front Cover Focus FANUC’s annual automation showcase Service XYZ Machine Tools puts customers first CNC Machining Machine tool investment pays dividends
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Sheetmetal Raising the bar with Bystronic
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Grinding Continued growth in precision tooling Composites Manufacturing Partnership pushes new frontiers Quality & Metrology Bowers boosts efficiency in compliance
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CNC Spotlight Dugard delivers
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Welcome... Welcome to issue eleven of Machinery & Manufacturing magazine. Crafted by our team of dedicated Engineering Media professionals especially for you, the CNC machine tool intensive manufacturing community. With a passion to support the metalworking & manufacturing sector, we invite you to enjoy an immersive reading experience. 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.
Additive Manufacturing The new Meltio Robot Cell Automated machining Mould maker embraces automation Autosport Mini engine races to Brands Hatch Turning New inserts Mitsubishi Materials Supplier Spotlight ASG wins contract with Airbus Show Preview Advanced Engineering UK
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Get in touch! hello@machineryandmanufacturing.com Need to advertise?
Time to get physical
In the modern world of manufacturing it’s easy to get lost behind a digital screen. Almost everything takes place virtually these days, whether it’s designing a product, creating a process, telling a machine how to make a component or generating a digital twin of your production line. Publishing is not so different. Here at Machinery & Manufacturing we pride ourselves on taking a truly hybrid approach: complementing our print run is a feature-rich digital issue where you can click or scan play buttons to access instant product videos and brochure downloads. It’s a reflection of modern manufacturing. This digital world, however, while extremely practical and functional to meet the demands of a fast-paced and dynamic manufacturing arena, is a step removed from real life. It’s important we that don’t forget to connect with people in person. Get physical from time to time. Exhibitions are among the best facilitators of this approach. For instance, we’ve just returned from EMO in Hanover, the world’s largest machine tool show with its vast halls and thousands of exhibitors. Back here in the UK we’ll soon be off to Advanced Engineering (1-2 November, NEC), then on to Southern Manufacturing (6-8 February, Farnborough) and MACH (15-19 April, NEC). These in-person events are a fantastic opportunity to meet with our readers and the wider manufacturing community. We can shake hands, give out printed copies of our show issue and have a chinwag. Networking is the modern term, I believe. But in all seriousness, it’s a really important chance to add some texture to an otherwise increasingly digital way of life. The coming months represent a showcase of industry where the UK manufacturing community has the opportunity to meet up, discuss their production goals and challenges, explore the latest technologies, and make new contacts. Come on, it’s time to get out there and say hi. Face to face. Laura Crawford Laura Crawford, Editorial Director
Catch up
JLR announces 300 new jobs in the Midlands
JLR recently announced it is recruiting 300 new technicians and test engineers in the West Midlands. The roles will support the continued growth of Range Rover production and development of next generation electric models. Of the 300 roles, the UK-based luxury car manufacturer is recruiting around 100 maintenance technicians for its Solihull plant to operate and maintain highly automated, precision, production facilities in a new body
shop costing around £130m. The new body shop will support an intended increase in Range Rover and Range Rover Sport production by 30% in future quarters. Alongside this, technicians will also be trained to work on an additional approximately £70m new body production system to support production of the highly anticipated new electric Range Rover at Solihull. www.jaguarlandrover.com
CERATIZIT launches PCF standard
invoices. Detailed information on the PCF of the corresponding products can be requested as an additional service. “The start of the systematic introduction of PCF figures in our product portfolio is an important milestone. Not only do they allow our customers to calculate their own corporate carbon footprint more accurately. The PCF figures also provide the basis for setting up a strategy to reduce their own emissions,” Executive Board Spokesman Dr Andreas Lackner commented on the launch of CERATIZIT’s PCF offering. www.ceratizit.com
At EMO 2023 , CERATIZIT introduced the first Product Carbon Footprint Standard (PCF) for carbide products. Since 18 September, the PCF classification of the first wave of products is displayed in the shop and on all
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Machinery & Manufacturing
Catch up
Production of iconic islander returns to Britain
Britten-Norman has launched its new production line at Bembridge as it repatriates manufacturing of the Islander aircraft back to the UK. Industry experts, customers and the press gathered at Bembridge as the new production line of the ‘Land Rover of the skies’ was officially opened by Bob Seely MP. Those present included Alex Norman, the son of co- founder Desmond Norman. From now on, the iconic Islander aircraft, variants of which have been manufactured by
the company for more than 50 years, will be built at Bembridge before being transported across to Lee-on-Solent for final assembly. The 1st Islander to be built in the UK since operations moved to Romania in 1968 is expected to be completed by May 2024.
Seco has launched a drastically updated visual identity as well as a long-term brand strategy. The company is describing this as the first in a sequence of major steps, as the business positions itself as a leading global name for industry innovation, efficiency, and sustainability. “We wanted our new brand to look clean, contemporary, and ready for the future.” says Bettina Palmen, Brand Manager at Seco. www.secotools.com Seco embraces a new look
Mazak recognised as leading employer Mazak stands out as one of just 12 businesses in the region to be awarded the Cornerstone
Certificate by Worcestershire County Council’s Local Enterprise Partnership. It celebrates employers with a deep-rooted culture of fostering the next generation of talent and an on-going commitment to nurturing the future workforce. The company employs over 600 people at its European Manufacturing Plant in Worcester, which has the capacity to build over 1,000 machine tools a year. Max Jones, People Development Manager, for Yamazaki Mazak UK commented, “Yamazaki Mazak UK is delighted to be recognised as a Cornerstone Employer by Worcestershire County Council. We are very proud of the work we do within local schools, colleges and organisations to support young people in achieving their goals and aspirations for the future. As a global manufacturer of world class machine tools, we are committed to the principle of excellent corporate citizenship.” www.mazakeu.com
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Machinery & Manufacturing
Catch up
Aurrigo claims ‘export’ first
Aurrigo International plc celebrate a major ‘export’ win as it deploys its autonomous transport technology in mainland Europe for the first time. The Coventry-based company, which recently celebrated its 1-year listing on AIM, will see its Auto-Shuttle vehicle take to the cobbled streets of Prague as part of the €275,820 EU-funded Living Lab for Autonomous Public Transport Project. Led by University College London (UCL), the cooperation between industry, municipalities and operators will see the autonomous vehicles run with a safety driver on board, while working towards a goal of using remote supervisor monitoring, signalling a new era in autonomy in
public transportation. Initially starting in the Czech capital, the project will also be running across Brno and Milton Keynes. www.aurrigo.com
Hexagon empowers machine shop operational excellence
Hexagon’s Manufacturing Intelligence division announced today the release of HxGN Production Machining, a new suite of software developed to empower machine shops to achieve operational excellence in the manufacturing of discrete parts, tools, and components with machine tools at any scale, from one-off prototypes to volume
production, and across industries ranging from medical to aerospace and beyond. Capabilities of the suite include CAD for manufacturing and design review, CAM for CNC machine-tool programming, process simulation and G-code verification and optimisation, shop- floor production intelligence, and automation and
collaboration powered by Nexus, Hexagon’s digital-reality platform. Central to the company’s Machine Shop Excellence solutions, the suite includes significant automation and innovative technologies that help manufacturers achieve highly efficient utilisation of material, cutting tools, and CNC equipment, and capture and consistently apply a shop’s best practices.
Attend the webinar
Machinery & Manufacturing 10
Catch up
Increase sliding-head turning productivity
When grooving components radially, axially or internally to micron precision on a sliding-head lathe, or when carrying out longitudinal turning or parting- off, production output may be raised following the introduction of a redesigned insert clamping method by cutting tool manufacturer, Horn. Its S224 grooving system formerly used a clamping screw on the front of the holder, but it has now been relocated to the side and changed Group Rhodes to showcase innovations for aerospace Group Rhodes will be showcasing its innovations in superplastic forming and diffusion bonding at the Advanced Engineering exhibition (1-2 November) at the NEC, Birmingham. The company will also highlight its extensive range of state-of- the-art machinery for hot and cold forming of metals and composites, and complete turnkey solutions for specialised machinery within the aerospace industry. Group Rhodes’ operations director James Gascoigne said: “The Advanced Engineering Exhibition is a great opportunity for our team to demonstrate the innovative work that is being undertaken at Group Rhodes. It is the perfect environment for us to meet with industry experts and discuss all the aspects of our ever-growing portfolio.” www.grouprhodes.co.uk
to a cam lock action. It means that an insert can be indexed or replaced quickly without having to remove the holder from the lathe. The
screw is readily accessible from the front when the tool is sitting in the gang toolpost and the insert can easily be removed or secured using a torque wrench and star bit. The process of presenting a fresh cutting edge to the component is therefore faster, reducing downtime and maximising productivity. www.phorn.co.uk
Unison enjoys a fantastic FABTECH FABTECH 2023 Chicago proved to be a huge success for Unison Ltd. Over the course of the four-day event in September, the tube and pipe bending machinery manufacturer secured a significant number of high-quality enquiries. Paul Krickeberg, CEO of Sharpe Products, one of North America’s leading specialists in custom tube and pipe bending and tube laser cutting, also visited Unison Ltd’s show booth to view the all-electric Unison Breeze CNC tube bender that would soon be on its way to his company. www.unisonltd.com
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Catch up
NSK awarded Bosch Global Supplier Award
At the prestigious Bosch Global Supplier Awards 2023, NSK was selected as one of just 46 top suppliers from approximately 35,000 companies that provide parts to Robert Bosch GmbH (Bosch) globally. NSK gained recognition in the category of Raw Materials and Components for superior quality and excellent performance as a supplier of the Bosch Group, a leading global supplier of technology and services. Every two years, Bosch honours the pick of its suppliers from around the world with the Bosch Global Supplier Award. This year, NSK´s esteemed award in the Raw Materials and Components category underscores the
company´s exceptional performance as a global supplier of innovative motion and control solutions, and its commitment to excellence in mobility and across wider industry. www.emerson.com/esg
Five-axis Milling Solutions
Recently, ISCAR unveiled a new family of segment endmills which utilize the single insert tool design principle. It is a known fact that the accurate parameters of a single-insert tool are lower when compared to a cutter with exchangeable carbide heads, not to mention the solid carbide endmill. Precision can be compromised if we analyse how a single insert tool, with two teeth, can compete against a multi-flute SCEM or carbide head tool. To dissipate the arisen doubts about the reasonability of the single insert segment tool design, we should consider several aspects.
The single-insert tool concept facilitates cost-effectiveness by expanding the diameter range of segment mills. These cutters feature nominal diameters of 16-25 mm. A durable insert structure and highly rigid insert clamping enable increasing the feed per tooth in comparison with the feed values that are recommended for solid carbide endmills and exchangeable heads. This ensures an appropriate level of feed and speed to machine productively. When operational stability is poor, decreasing the number of teeth contributes to vibration control. Inserts mounted on the BALLPLUS tool family can transform the tool to a segment endmill by use of inserts only. ISCAR BALLPLUS tools include a diverse choice of tool bodies, adapters, and extensions, which greatly simplify tool customization. Choosing a single-
insert segment tool design is now more logical and justified. www.iscar.co.uk
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Machinery & Manufacturing
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Subcontractor exclusive
Hidden gem Technical Editor Steed Webzell gains rare insight into the world of diamond tooling thanks to an exclusive chat with John Emptage, Sales Manager at DK Holdings.
milling cutters are ideal for working on materials like hardened steels, titanium, nickel alloys and broad spread of engineering composites. Special measures While DK Holdings can despatch off-the- shelf products as part of a next-day delivery service, bespoke diamond tools make up a large proportion of the company’s offer. “We partner with customers to create specials using our experience and technical expertise to add value and create the optimal solution,” explains Sales Manager John Emptage. “Customers come to us with a new process,
The small town of Staplehurst in rural Kent is an unlikely place to find one of the UK’s foremost manufacturers of diamond tools. But this is the home of DK Holdings, an ISO-accredited designer, manufacturer and supplier of high- quality diamond tooling with experience stretching back to 1959, the 85-employee company is now undertaking a new challenge: driving growth in its recently introduced subcontract machining service. DK Holdings supplies off-the shelf and bespoke diamond tooling solutions to a variety of industries and applications. Diamond tools such as grinding wheels, drills, reamers, routers and
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Subcontractor exclusive
seeking optimisation. We have many long- serving, qualified engineers on site who are highly experienced in delivering the best possible outcome. In addition, we work with many research centres and universities in the UK.” He continues: “There’s so many diverse applications that require a bespoke diamond tool, including medical prosthetics, wind turbine blades, Formula 1 cars, tobacco manufacturing machines and railway bridges, and we’re involved in developing successful and stable manufacturing processes for all of them. Yes, we have some big international competitors that offer diamond tooling, but most want to sell you a nearest-fit standard product. And in many cases you won’t be able to buy direct; you’ll have to go via a catalogue distributor.” Get the green light Aftersales support is a further service that sets DK Holdings apart from its competitors. Stripping and re-plating a diamond tool not only saves up to 40% against the cost of buying new, it also renders old bodies reusable, making it a green process in many ways. And that is one of just many environmental initiatives at DK Holdings. For instance, the company recently added another 585 solar panels to its production facilities. Alongside the 50kW already in place, DK Holdings can now produce 33% of the energy required to run its site annually via solar power. This huge investment delivers an estimated annual CO2 emission saving of 60tCO2e/year, the equivalent of planting 2,770 trees. On the subject of trees, DK Holdings has now planted over 240 trees through its Gold Membership with The Green Organisation, while the company is also in the process of replacing its business fleet with electric cars. As a whole, the sustainability efforts of DK Holdings have not gone unnoticed: the business
recently gained EcoVadis Silver medal status, an accolade dedicated to recognising, rewarding and promoting environmental best practices around the world. DK Holdings was in the top 18% of companies undertaking the survey in 2022/23. Need capacity? At the heart of DK’s environmentally friendly operation is its 4000m2 state-of-the-art production facilities, which comprise four fully equipped workshops. The company recently decided to put its manufacturing excellence to further use by introducing a subcontract machining service. “We have a vast selection of machinery on site for manufacturing our diamond tools, so “We have a vast selection of machinery on site for manufacturing our diamond tools, so thought why not use some of that capacity to serve others”
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Subcontractor exclusive
diamond tooling solutions worldwide and is in no mood to surrender its market-leading position. “Yes, there’s competition from manufacturers based in low-wage economies, but we’re not in that space,” states John Emptage. “Rather than high-volume standard solutions at a low prices, we seek to add value and utilise our skills in support of customers. This way, we can always ensure the delivery of an optimal solution that maximises return-on-investment.” Moving forward, the company is looking to expand its market reach and revenues at home and abroad, a task not without its challenges. “Brexit has been kind in some respects but not in others,” he concludes. “We’ve seen some benefit from customers reshoring that in turn opened up new sectors and markets for us to explore, whilst rebuild our existing partnerships overseas. We also work closely with the Department for Business and Trade to find ways of further extending our export reach. We’re an ambitious UK manufacturing company that constantly strives for more growth.” n
thought why not use some of that capacity to serve others,” says John Emptage. “We were getting so many requests that it seemed a natural progression to make it an official service. As a business we have the skills, experience and the machinery to make subcontracting a real success. We continue to invest in the purchase of new machines, including CNC turning centres with twin spindles and driven tools. We also have CNC milling, wire erosion, grinding, pressing, CADCAM and inspection capabilities, which enable us to offer larger production runs, smaller batch component manufacturing or a one-off special.” DK Holding’s machining capabilities and team of skilled engineers make it possible to produce precision engineered components in a wide variety of materials, everything from aluminium and steel through to tungsten carbide. “Although cutting-edge machinery is vital, we have a fantastic team of production staff whose dedication, experience and expertise are supported by our ISO9001-accredited quality department,” says John Emptage. “We’re also nurturing the next generation of talent through our apprenticeship scheme, a strategy that simultaneously contributes to long-term business continuity. We see the threat posed by a lack of new skills as a potential obstacle to our ongoing success, which is why we invest heavily in this area.” The company firmly believes
www.dk-holdings.co.uk
that apprenticeships are crucial to a thriving business, combining the skillset of its experienced workforce and coupling it with new ideas. This approach leads to increased productivity and the continuous development of new products. And products are of course what this progressive business is all about. The DK Holdings name is synonymous with the design, manufacture and supply of
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Lets talk: Injection moulding
In an exclusive interview, Samuel Guest, Product Manager at Protolabs, speaks with Technical Editor Steed Webzell about the company’s innovative injection-moulding capabilities The shape of things to come
There are numerous myths around injection moulding, many of which suggest the process is expensive, complex and requires long lead times. Protolabs is on a mission to expose these myths for what they are: incorrect. It is time to set the record straight. While Protolabs historically focused on the prototype market, today the company finds itself also meeting the production requirements of customers in sectors that include consumer products, medical, automotive, aerospace, electronics and many more. “The moulding industry is shifting beneath us and we are a major contributor to this changing dynamic,” states Product Manager Samuel Guest.
“More and more companies are seeking suppliers who can offer technical expertise, quality and speed in both prototyping and production projects.” At the heart of Protolabs’ offer is automation, which allows the company to provide injection- moulded parts in lead times as short as one day in some cases. “In this instance, we would make the tool from aerospace-grade aluminium,” says Guest. “The assumption that injection moulded parts take months is simply misplaced.” Protolabs expedites the process by automating CAD model analysis up front, a 24-hour service provided free of charge. The
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Lets talk: Injection moulding
company then presents any risks or issues to the customer, who in turn can choose to make design changes or accept the risks and proceed to manufacturing. Customers are able to upload their design iterations as many times as they like to get valuable feedback. Protolabs engineers are also on hand to discuss the component as part of the company’s in-house consultative design service. “Essentially, as soon as a customer hits the order button on our e-commerce platform, the wheels are in motion, straight into automated scheduling,” explains Guest. “Automation doesn’t just enable better costings, it also supports shorter lead times. Our software is a live system, so if an urgent order arrives it will re-prioritise in real time.” The Protolabs factory at Telford never runs at full capacity. The company sets a certain percentage of full capacity to act as a trigger point, where reaching this threshold prompts investment in more machines or personnel to remain ahead of the curve. As a general rule of thumb, component complexity determines the lead time, coming in at an average of 15 working days. The Protolabs software will offer shorter lead times (as fast as one day) at a changing premium, with customers able to decide before they order. “We can get up to 2000 parts from a prototype tool,” reports Guest. “However, customers can pay to upgrade to a production tool with unlimited part runs. When the tool wears out we’ll simply replace it free of charge. Customers also get a reduced piece-part cost as part of the upgrade.” Along with standard plastic injection moulding, Protolabs offers over-moulding and insert moulding, processes that are becoming increasingly popular to reduce the number of parts in an assembly. In addition, Liquid Silicone Rubber (LSR) moulding is available, which the company says few others offer, particularly as a prototyping service. Beyond moulding, companies
can also turn to Protolabs for CNC machining and 3D printing. “Most assume 3D printing is a threat to injection moulding, but injection moulding becomes cheaper than 3D printing at volumes far lower than many think,” explains Guest. “That number could be as low as 75-100 parts, at which point the tool has pretty much paid for itself. Of course, there is a place for 3D printing, but we get more and more customers asking us to 3D print a part and we find ourselves explaining that injection moulding would be cheaper and quicker in many instances. Another myth busted.” Protolabs moulds around 4.4 million parts a month. The company recently expanded with the addition of a production facility that doubled its floor space, leading to considerable investment in machines, as well as both automation hardware and software. “We are growing, but
there’s real variety in where that growth is coming from,” conclude Guest. “We have to be very adaptable and remain industry-agnostic, so we can pivot accordingly. This is the best way to ensure we continue meeting the needs
and expectations of all customers, regardless of sector or size.” n
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Machinery & Manufacturing magazine discovers the person and career path behind the rapidly growing social media phenomenon that is Chloe the Welder Chloe the Welder. Heard of her? If not that’s a surprise as Chloe has become something of an online sensation. With more than 11,000 followers on Instagram and thousands more on TikTok and X (formerly Twitter), in welding terms Chloe is a bona-fide celebrity. She even has her own website offering merchandise. So who is the person behind the (welding) The Career Files Bright spark Chloe Sales (Chloe the Welder) Alpha Manufacturing
She currently works at the company’s Stafford facility (Alpha Manufacturing Chemical Technologies), where she performs TIG welding involving high-grade titanium and nickel. Doing so well at work, Chloe plucked up courage to request her own welding bay, somewhere she could learn new welding skills and undertake special projects after hours – somewhere she could be Chloe the Welder. Alpha Manufacturing duly bought her a shipping container and converted it into a workshop. “With my social media profile gathering pace, I also started receiving approaches from sponsors, like welding equipment manufacturer Miller Electric, who kindly donated equipment.” Now 28, Chloe is about to take a break from welding and start her biggest life-change to date by shortly giving birth to a baby boy. Who knows, maybe another welder in the making? Good luck Chloe. n “With my social media profile gathering pace, I also started receiving approaches from sponsors...”
mask? Meet Chloe Sales, currently an apprentice-qualified welder at Alpha
Manufacturing, a multi award-winning, custom metal fabrication company in Staffordshire. Chloe’s journey into welding came about largely by chance. As a schoolgirl, she had “no idea” what she wanted to do. She tried courses in both health/social care and hairdressing, but neither felt right. As a stop-gap, Chloe took a temporary position in a warehouse at an engineering company, where she learnt of the company’s struggles to recruit welders. She put herself forward and subsequently enrolled on a Level 3 Advanced Apprenticeship in Welding and Fabrication at Stoke-on-Trent College. “I went on to become STEM Apprentice of the Year at my college,” she says. “Journalists started getting in touch and schools wanted me to give talks. That was the origins of Chloe the Welder.” Four years ago, changes at her employer prompted Chloe to join Alpha Manufacturing.
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3-5 OCTOBER 2023 TURNING CENTRE OF EXCELLENCE HURST BUSINESS PARK BRIERLEY HILL DY5 1UF CITIZEN MACHINERY OPEN HOUSE 2023
Materials
Metals sector embraces new trading innovation
One of the biggest innovations to boost the metals industry in more than 50 years has reported a promising first nine months.
SteelBuy, an easy-to-use online marketplace where businesses can buy and sell metals quickly and securely, has recorded over 300 transactions and £1m+ sales revenue since it was launched at the start of the year. Users from across the UK are leveraging the technology to achieve faster and more efficient deals for their mild steel, stainless steel, and aluminium, with all the logistics and invoicing managed through the encrypted platform. Sellers can post their material with product specifications, test certificates and price per tonne and these can be found by potential buyers within seconds. With listings taking just
one minute to complete, it is estimated that 37 hours can be saved each week in the average purchasing and sales function. Importantly, all transactions are anonymised so buyers and sellers do not know who the other party is, essential when sensitive data, such as prices and stockholding, must remain confidential. “This is much more than just a place to buy and sell materials,” explained Terry Sargeant, CEO of SteelBuy.
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Materials
with the average delivery time of metal, from listing to arriving at the buyer, at just three days. “This is
transformative for both parties. When it comes to buying steel and aluminium, deals often take too long to complete, with lead times
traditionally excessive (up to 12 weeks for mill production) – we can reduce this by almost 90% by matching supply and demand. “For sellers, we deliver greater market visibility and reach for both your surplus metals and commodity products. By using our online platform, they have an opportunity to sell to anyone, from anywhere and not have to worry about relationships, payment terms or credit risks. SteelBuy removes all the hassle.” Shirley-based SteelBuy has ambitious plans to take its technology into the European marketplace, as well as rolling out new features that reflect user feedback to make the process even easier. The company will be making its first public exhibition appearance this week, when it looks to showcase the huge benefits of its online platform on Stand F50 at the UK Metals Expo (13-14th September) in Birmingham. Terry concluded: “We have big plans, and we won’t stop until SteelBuy is the largest global online marketplace for the metals industry. “Initial feedback has been really encouraging, not to mention the 300% growth in transactions we’ve seen over the last six months.” n
“We are not just providing an exciting new channel for customers to buy and sell metals, we are selling a vision of the future of the industry.” He continued: “SteelBuy enables users to effortlessly digitalise their purchasing and sustainably modernise their business and this is just the start – there’s so much unexplored potential in materials trading and distribution, through the power of digitalisation. “The metals sector is traditional by its very nature, yet just eight months after our launch and we have proven time and time again that we can reduce costs, boosts sales and speed up what can be an extremely time-consuming process.” SteelBuy was the original idea of Cameron Sargeant, who came up with the idea of selling material online whilst working in sales for thyssenkrupp. 22 people were recruited for the new venture, a mix of software, marketing, sales and engineering experts, who all share a passion for harnessing the power of digitalisation in the metals industry. Terry, who has been involved in the sector for more than 40 years, went on to add: “We’ve got producing mills, steel service centres, stockholders and even traders using our platform,
www.steel-buy.com
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Aerospace manufacturing
Productivity takes off ‘Push Your Productivity’ was the theme this year of Starrag’s Tech Days – a manufacturing extravaganza open house at the company’s headquarters in Switzerland. Numerous machines and complementary manufacturing technology demonstrations highlighted how customers can benefit with shorter lead times and lower piece part costs from Starrag’s world supremacy in the machining of aero components such as blades, blisks, impellers, casings and structural parts.
The 250 plus visitors from 17 countries witnessed a seemingly endless flow of
only on improved cutting of complex shapes in difficult materials but also on the challenges of producing higher volumes (using automation). There were presentations of how Starrag machines can improve productivity including how a Droop + Rein FOGS machining centre is meeting the challenges of machining and matching aluminium alloys and carbon fibre parts to an accuracy of 55 microns. Also, a TTL software animation showed how the software can effect a blade repair at 20%-30% the cost of a new blade, plus details of a new spindle drive unit, an 18,000 revs/ min HSK-100 for all-round metals machining –
manufacturing expertise to help them achieve bottom line savings in the production of such workpieces, and not least, he launch of the new ultra-rigid and robust titanium-cutting horizontal machining centre, the STC 1250 HD, the first machine in its class with hydrostatic guideways boasting zero friction/non-stick/slip in the X axis. They witnessed the Ecospeed F machining centre - the latest addition to the machines in the facility’s Aerospace Competence Centre. Simultaneous five-/six-axis machining of landing gear parts on large-capacity mills, focusing not
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Aerospace manufacturing
complemented by an array of complementary technologies being demonstrated by the companies which ‘partnered’ Starrag for the event. Siemens demonstrated its Sinumeriuk CNC system with Digital Twin software which effectively creates a closed loop between digital design, machining simulation, CAD/ CAM and post-processing to not only minimise the programming of complex parts but also to eliminate costly material test cuts. Caron Engineering showed how its Tool Adaptive Control system can run tools at up to 25% higher rates and extend tool life by up to 25% by process monitoring via sensors for power usage, vibration, and coolant pressure and flow, for example. Hexagon Metrology hammered home the ‘time costs money’ message while demonstrating its NC Measure machine tool probing/measurement/toolsetting expertise that integrates the results from a multi-sensor radio wave receiver. Live demonstrations showcased the impressive capabilities of the new STC 1250 HD on titanium using porcupine, face and rigid milling tools, and how its 12-tonne column can be easily moved by hand! The machine - the first in its class featuring hydrostatic guideways with zero friction/non-stick/slip in the X axis (so, no wear and reduced maintenance compared with conventional box guideways) achieved unmatched roughing times and dynamic finishing of resulting more precise parts - indeed, it is capable of reducing roughing times of structural parts by over 50%. On one test part – a frame door forging of Ti6A14V and measuring 80 mm deep x 300 mm wide and 1,220 mm long – the machine’s roughing and machining time savings also demonstrated a 33% reduction in energy consumption.
With pallets of 1,000 mm by 1,250 mm capable of accommodating workpieces up to 2,200 mm by 1,950 mm, the machine has a torque rating of 30,00-50,000 Nm, a 80 mm drive chain (compared to the traditional 63 mm) and it can achieve roughing cuts up to four times deeper in titanium than traditional machines. The in situ Ecospeed F 1540 machining centre is the smallest of the Ecospeed family but like its stablemates, uses Starrag’s Sprint Z3 machining head to impressive effect - the Ecospeed is unmatched at aluminium removal, hence the dramatic time saving of the aerostructure part from 14 hours to just three hours and 40 minutes. Starrag has been meeting the challenges of landing gear machining since the early ‘90s and today utilises simultaneous multi-axis machining (in one case, on a Droop + Rein FOGS HD mill, simultaneous six-axis operation) to produce the highly-accurate complex shapes in difficult materials, as well as STC and Heckert machining centres for smaller workpieces – the latter undertaking turning as well as milling. By understanding the challenges and combining highly-efficient machines and tooling, Starrag emphasised that it cannot only improve cycle times but also cut the number of tools used and reduce the loads on those tools – which Machinery & Manufacturing 25
Aerospace manufacturing
global aero market is back on track - CEO Martin Buyle also identified one of the ways forward for Starrag and all its product ranges of Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP, Starrag and WMW machines. “Starrag historically has never competed on price and quantity - we’ve always focused on competence and reliability – and each of our product ranges is undoubtedly the best in its respective field coupled with our globally- recognised expertise in applications engineering and stand-alone machine systems solutions,” he said, “whether that be in aerospace, transport or wind energy, for example.” He continued: “Our customers consider the true cost of machine ownership, considering life cycle savings for every component. We are adept at all aspects of helping them achieve manufacturing savings and now it is time for us to ensure that everyone throughout the world – and in every industry sector including defence, medtech and luxury goods, for instance, knows that!” n “Starrag historically has never competed on price and quantity - we’ve always focused on competence and reliability”
equates to higher tool life and lower overall tool costs. The keynote address at the two-day event by Dr Matthias Lange from Premium Aerotec (formerly part of Airbus) not only highlighted the rising demand for passenger aircraft – forecast to be 40,000 new aircraft for delivery between 2022 and 2041 – but also pinpointed how this best-in-class Tier One aero machinist is driving up sustainability in its own manufacture. This complements the engine manufacturers’ quest for fuel burn reductions of 20%-40% and, for example, improved end-of-life recycling, optimised noise and emissions, and improved design and manufacturing methods as well as more effective and efficient supply chain initiatives. The company annually produces around five million parts in 25,000 variants at different locations in Germany and Romania. Dr Lange focused on Premium Aerotec’s use of electricity (and photo-voltaics) and said that most the highest energy use at the company was in machining, so the target is to reduce this by working closely with suppliers for improved [milling] routines, more effective use of coolant and improved tooling. Optimised feed rates, and better process and tool wear monitoring will all contribute to savings via the consumption of less energy per part, he added. While acknowledging Starrag’s inherent aerospace expertise – and pleased that the
www.starrag.com
26 Machinery & Manufacturing
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Talking Tech: Tooling for Aerospace
In discussion with Mark Radcliffe, Business Development Manager (Aerospace) at MAPAL, Technical Editor Steed Webzell learns there is far more to this innovative tooling company than many are aware. FLYING HIGH
Although historically a renowned market leader in the automotive sector, tooling expert MAPAL is also a significant player in the aerospace industry following a concerted effort to infiltrate this segment over
of simultaneously machining materials with very different properties, while still delivering impressive tool life.” Accuracy is another important factor. Here, MAPAL tools can perform the one-shot drilling of multi-stack materials within tolerances of 50-60µm. “The point geometries and how we
the past 15-20 years. Today, the company’s tooling is in use at most major aerospace OEMs and MAPAL is now targeting greater penetration at tier one and tier two supply chain manufacturers. Tooling solutions from MAPAL are available for aerospace structural and engine materials that include aluminium, CFRP (carbon fibre reinforced plastic), titanium, stainless steels, superalloys and more. Many structural parts are single materials, but some assemblies feature multi- stack materials involving aluminium- CFRP-titanium or CFPR-stainless steel, for example. Tool geometries and coatings therefore demand high levels of design innovation. “Diamond-coated tools work well on abrasive CFRP, but are not ideal for titanium,” explains Mark Radcliffe, Business Development Manager (Aerospace) at MAPAL. “We use advanced geometries and coatings to overcome the challenge
use the margins ensures successful drilling to tight tolerances without delamination” he adds. “We’re currently involved in a project that requires reducing the burrs on aluminium exit to less than 100µm.” Today, MAPAL has a standard tool catalogue for its aerospace customers dedicated to titanium and superalloy workpieces. Its pages include information on the latest high-feed milling cutters, indexable inserts and high-speed drills, for instance. A similar catalogue is available for aluminium parts, covering different types of carbide and PCD tooling. R&D is ongoing. A case in point is MAPAL’s new (released at EMO 2023) OptiMill-Alu-Wave solid- carbide roughing cutter for aluminium workpieces. This exciting new cutter can achieve staggering metal removal rates of up to 21 litres per minute on structural parts such as wing ribs and
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Talking Tech: Tooling for Aerospace
wing skins, which will prove highly appealing to tier-one and tier-two manufacturers. “Due to tight profit margins, we find supply chain manufacturers very receptive to any new tooling innovations that can deliver genuine competitive gains,” explains Mark Radcliffe. “They seek out cost-effective tools able to reduce cycle times and cut costs, without any compromise in tool life or quality. Our new OptiMill-Alu-Wave scores on all fronts.” Drilling, reaming, milling and trimming are MAPAL’s core aerospace competencies, typically involving solid-carbide and indexable- insert cutters, as well as holders. Regarding the latter, a recent innovation is the company’s Mill Chuck for hard metal machining applications, which avoids the issue of shrink-fit holders that gradually loosen their grip on the cutter as heat increases. Mill Chuck provides physical contact with the tool, delivering 900 Nm of clamping force regardless of temperature. The result is no more pull-out or push-in during hard metal machining, resulting in a far more rigid process. As a matter of course, MAPAL benchmarks all new products against comparable offers from competitors, refusing to release any new innovations that are not among the top three performers. The company has many aerospace
case studies that highlight the gains available from such rigorously assessed tools. “We had a project involving titanium where we reduced cost per part by 200%,” states Mark Radcliffe. “Another example saw us reduce the cycle time of a process involving an indexable- insert cutter from 6.5 to 3.5 hours per part. Delivering an annual cost saving in excess of £250k. In all cases we scrutinise the whole process up front to identify the optimal way of generating savings for customers.” Many aerospace tools are of course specials, particularly those for OEMs. In these instances, MAPAL conducts a comprehensive review of the application and project objectives before delivering a proposal (with input from the company’s Competence Centres in Germany, if required). “The design and manufacture of specials takes place in the UK,” says Mark Radcliffe. “Once complete, customer trials take place as part of an iterative testing process that will continue until we meet the project’s objectives.” Tooling solutions for aerospace customers today represent 30-40% of MAPAL’s UK revenue. With even more growth anticipated moving forward, this is clearly a business in full flight. n
www.mapal.com “We use advanced geometries and coatings to overcome the challenge of simultaneously machining materials with very different properties, while still delivering impressive tool life.”
Watch the video
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