Machinery & Manufacturing | Issue 12 | Nov/Dec 2023

Magazine Highlighting Machine Tool and Manufacturing Technology

HIGHLIGHTING MACHINE TOOL & MANUFACTURING TECHNOLOGY

ISSUE 12 | NOV/DEC 2023

SCAN THE CODE USING YOUR CAMERA APP TO READ THE DIGITAL VERSION

Page 38 XYZ Machine Tools Ready to celebrate 40 years in 2024

WATCH VIDEO

Storage & Sawing: The holistic solution

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Revolutionising EV Vehicle propulsion & handling

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Event Preview: Southern Manufacturing returns in 2024

EDM The right tool for the job

LET’S TALK : MICRO MACHINING Micro tools macro benefits

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Contents 5 Thought : Make your voice heard Tell your story

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

What’s been happening?

The Career Files A risk-averse approach CNC Machining A new dawn

Talking Tech : Micro machining We discuss micro tools with macro benefits Manufacturing Solutions Storage & Sawing : The holistic solution

Tooling Technology From the shed to the sky... Grinding Addressing consumable spend

Published in an eco-aware format by Engineering Media Ltd.

Company Number : 13634129 VAT Registration 397 8226 41 Our registered office address is :

EDM The right tool for the job

20-22 Wenlock Road, London, N1 7GU Maidstone Office : +44 (0)1622 296112 In our mission towards carbon neutral, we publish and replant in partnership with:

3D Printing Ryse 3D targets major growth

Front Cover Focus XYZ Machine Tools ready to celebrate 40 years!

Supplier Spotlight On a roll... Turning Technology The Empire strikes back

EV Manufacturing Revolutionising propulsion and handling Skills Tap into skills of the aging workforce

© All rights reserved. Machinery & Manufacturing along with it’s contents, should not be copied or transmitted in any format without seeking prior consent from Engineering Media Ltd. You can read our privacy policy by visiting www.machineryandmanufacturing.com where you will find more detail about how we protect your data. The contents of Machinery & Manufacturing does not imply our endorsement, where interviews and articles contain views, they do not necessarily reflect the views of our editors.

Mould & Die Guhring releases innovative tools

Machine Tool investment HEL Performance makes £1.4m investment

Welcome... Welcome to issue twelve of Machinery & Manufacturing magazine. Crafted by our team of dedicated Engineering Media professionals especially for you, the CNC machine tool intensive manufacturing community. We invite you to enjoy an immersive reading experience. This is a hybrid magazine, to be read on or alongside your desktop, phone or tablet. Key: Watch video Download

Tooling The future of milling & turning Metrology Aberlink CMM goes full 3D Show Preview Southern Manufacturing 2024

Events Calendar Let’s all go!

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Are you are tired of reading about your competitors in trade magazines? Do you sit there thinking I’ve got a better story to tell? Perhaps you want to tell your story but don’t know how? If any of these scenarios strike a chord, we want to hear from you, whatever your company size. The importance of finding your voice and telling your story is paramount in today’s highly competitive manufacturing arena. Here at Machinery & Manufacturing we’re looking to unearth stories from companies without much history of engaging with the trade press. If you have something to say, we want to hear it. Maybe it’s about overcoming adversity, winning an award against all the odds or championing skills. In truth, however, it can be about almost anything: attracting new investment, launching a new product, installing your first five-axis machining centre, winning a new contract, acquiring another company, rebranding your business, taking on apprentices, engaging with charities, growing your turnover, holding an event – the list goes on. If writing is not your thing, no problem. Simply give us a call. We’re great listeners. What’s in it for me, we hear you ask? Well, plenty actually. Publicity drives customer engagement. Getting your story in Machinery & Manufacturing can grab the attention of both existing and potential customers, perhaps providing the opportunity to reach a previously untapped pool of orders. The bottom line is that telling your story remains one of the best ways to get in front of your target audience. Getting ‘published’ is also fantastic for building the credibility of your business. The industry views platforms such Machinery & Manufacturing, with its hybrid digital and print format, as a trusted source of information. So if you’ve got news and want to get the word out, look no further than Machinery & Manufacturing. We would love to tell the world your story. Laura Crawford Laura Crawford, Publisher Make your voice heard

Catch up

£4.5 billion boost for UK Manufacturing

The government has announced £4.5 billion in funding for British manufacturing to increase investment in eight sectors across the UK. The funding will be available from 2025 for five years, providing industry with longer term certainty about their investments. Over £2 billion has been earmarked for the automotive industry and £975 million for aerospace, supporting the manufacturing, supply chain and development of zero emission vehicles, and

investment in energy efficient and zero-carbon aircraft equipment. Alongside this, the government has committed to £960 million for a Green Industries Growth Accelerator to support clean energy manufacturing, and £520 million for life sciences manufacturing to build resilience for future health emergencies and capitalise on the UK’s world-leading research and development.

Rolls-Royce announces successful run of UltraFan technology demonstrator to maximum power

This is an important milestone for the UltraFan demonstrator, which was successfully tested for the first time earlier this year. Since then, the UltraFan team has been gradually increasing the power as part of the rigorous testing regime and the demonstrator has performed in line with our expectations. The results of the test will provide Rolls Royce with valuable learning and data, which their teams will now take away and continue to analyse. This achievement reinforces confidence in the suite of technologies that has been developed as part of the UltraFan programme.

Tufan Erginbilgic, CEO, Rolls-Royce plc, said: “Hitting full power with our UltraFan demonstrator

sends a strong message that Rolls-Royce is at the cutting-edge of innovation and technology, leading the way in the transition to more efficient and sustainable aviation. This fantastic milestone puts us in a strong position to support the plans of our customers as they develop the next generation of super- efficient aircraft.”

Machinery & Manufacturing

Catch up

Luke Insley has been appointed Area Sales Manager for South-East England by machine tool supplier NCMT. He is responsible for sales of the company’s product portfolio, which includes Okuma machining centres, CNC lathes and grinders, Makino machining centres, and photo-activated adhesive work holding systems manufactured by Blue Photon. With excellent knowledge of tooling and machine tool programming and operation, he brings with him a wealth of other experience likely to be of assistance to existing and prospective NCMT customers, such as work holding and fixture design. www.ncmt.co.uk NCMT appoints Sales Manager for South-East England Cambridgeshire engineering firm appoints new director

Excitement is in the air at Grenville Engineering after recently taking delivery of a Bison Tube Laser, marking a significant milestone for Grenville’s continuous pursuit of excellence in precision engineering. The RVD SMARTFIBRE TF 8020.3000 CNC Fiber Tube Laser represents the latest advancement in laser cutting technology. This state-of-the-art Bison machine is poised to expand Grenville Engineering’s capabilities and allow the company to work with a wide range of materials and shapes. Equipped with advanced features, it brings a new level of flexibility, ensuring that the company can cater to even the most unique of projects. Sales Director Stuart Rawlinson says, “Our new Tube Laser isn’t just a piece of equipment; it’s a game-changer for Grenville Engineering. This arrival elevates our ability to meet customer needs and enter new markets like never before. This clearly reflects our commitment to innovation, quality, and increasing capacity.” grenville-engineering.co.uk Investment for Grenville

Advanced Precision Technologies, which specialises in 5-axis CNC programming and manufacturing, has appointed Danny Speirs as a co-director, signalling the start of a phase of planned expansion. Danny brings with him 25

years of manufacturing engineering experience and joins the business after spending the last 12 years at Mercedes High Performance Powertrains. He will now work with founder and fellow director Thomas White on guiding Advanced Precision Technologies through a significant period of growth. www.aptechno.co.uk

Machinery & Manufacturing

Catch up

Dormer Pramet is pleased to announce the launch of its latest range of tooling systems. This new assortment features an array of cutting-edge milling, turning, drilling, and tapping clamping tools, as well as a variety of collets and Elevate Your Machining

accessories designed to seamlessly integrate with a wide spectrum of machines, from traditional setups to state-of-the-art CNC centers. In today’s dynamic engineering landscape, Dormer Pramet recognizes the growing demand for improved productivity and cost-efficiency. Dormer Pramet firmly believes that optimizing the tool and workpiece clamping process is pivotal to achieving these objectives. Proper

clamping is not just a requirement; it is essential for ensuring precise workpiece dimensions, delivering high-quality surface finishes, extending tool life, and reducing setup times, ultimately enhancing overall machine efficiency. www.dormerpramet.com

‘Building Your Future’ Open House

Yamazaki Mazak is hosting a special ‘Building Your Future’ Open House for customers who are ready to invest in new machining technology. The event will be hosted at the Mazak European Technology Centre in Worcester and will run from 5-8 December with a total

of 18 machines on show, including all the UK- designed and manufactured models. Mazak has made significant investments in its European Manufacturing Plant in Worcester this year. With a successful recruitment strategy which led to full employment of all the necessary skills to run

the factory at maximum capacity, Mazak is now building machines with very short lead times. To register for the Mazak Open House, please visit: discover.mazakeu.com/ openhouse-2023

Machinery & Manufacturing

Catch up

Walter introduces indexable inserts

Cutting tool specialist Walter has expanded its WL copy turning system with the introduction of the new WL17 indexable inserts for Swiss type automatic lathes and small diameter machining. Used on the W1011-S-P external turning toolholder, which is also a new arrival along with the W1210/W1211 boring bars, they bring the benefits of the existing WL25 inserts to smaller dimensions. The W1011-S-P toolholder has a square shank that is available in the most common shank sizes of 12 by 12mm and 16 by 16mm. They have been specially designed for use on automatic lathes and multi-spindle turning

centres. Walter is as yet the only manufacturer to offer a turning system for automatic lathes with positive engagement and three-edge turning inserts. As with the WL25 turning inserts and toolholders, the smaller indexable inserts facilitate equally high cost efficiencies. www.walter-tools.com DK Holdings Limited is pleased to be exhibiting at JEC WORLD, the leading International Composites Show, which takes place from 5th – 7th March in Paris next year. “We are excited to be back at JEC WORLD in 2024”, Sales & Marketing Manager John Emptage tells us. “Face-to-face networking with our global partners in the Composite industry is vital as it enables us to understand their requirements and develop Diamond tooling solutions to optimise production processes as well as assisting with new projects” “You’ll find us at Composites UK’s Pavilion for the first time since becoming members earlier this year which we are very much looking forward to. Attending as part of the UK trade community for the DK at JEC WORLD 2024

An Intelligent Move Tooling

Intelligence Ltd, a leader in Industrial Inventory and Asset Management

is thrilled to announce it has now moved to a new cutting-edge facility as part of its strategic expansion plans. Previously operating from three different sites, the strategic expansion has almost doubled the floor area to 5000sq/ft with an additional 3000sq/ft of offsite warehousing. The relocation supports increased assembly capacity and improved workflow to streamline production, better serving the growing customer base. Furthermore, the new facility provides a demonstration area and meeting suite for customers that is supported by a comprehensive service and support hub where customers can discuss their specific requirements. This marks a significant milestone in delivering exceptional

composite sector enables us to work with our fellow members exhibiting and share what innovative projects we have in the pipeline for our 65th Anniversary Year.”, John concludes. www.dk-holdings.co.uk

solutions across Europe and beyond. www.toolingintelligence.co.uk

Machinery & Manufacturing

Catch up

UK manufacturers boosted productivity by £9.4bn in last year Analysis of ONS data shows that UK manufacturers have achieved significant output and productivity improvements despite a slight slowdown in activity this summer

Q3 2022 and Q3 2023, while productivity per manufacturer was up 8.2%. On average, each active UK manufacturer produced goods worth £1.12m in Q3 2023, up from £1.04m the year before. The motor vehicles and transport equipment sector achieved the most significant year-on-year improvements. Output in Q3 2023 was £5.3bn higher than in Q3 2022, supported by a 19.7% increase in productivity worth £5.1bn across the sector. Chris Iveson, CEO at FourJaw Manufacturing Analytics, comments: “Manufacturers face significant challenges and uncertainties right now. However, many do so from a position of strength, having delivered improvements in output and productivity over the last two years.” “Order books have been growing from

The UK manufacturing sector was 6.6% more productive in the third quarter of 2023 than the same period in 2022, driven primarily by improvements in the automotive and broader transport equipment sector, according to analysis of ONS data from FourJaw Manufacturing Analytics, a technology company that measures machine productivity. FourJaw’s analysis, which informs its UK Manufacturing Productivity Index, shows that this productivity boost was worth £9.4bn to UK manufacturers and continued a run of improved manufacturing output and productivity going back to 2021. The total value of UK manufacturing output in the third quarter of 2023 was £152.4bn. Although this was £9.3bn more than the same period in 2022, it was £2.9bn lower than Q2 2023 – the first quarter-on-quarter reduction in manufacturing output since the start of 2021. Year-on-year improvements in output and productivity were achieved despite the number of active UK manufacturers falling from 138,000 to 136,000 in the same period. Output per manufacturer increased by 8.0% between

CMY

domestic and international markets, and we’ve seen manufacturers re-shore work that was outsourced overseas. That’s filled previously underused production lines, led to investment in new machines and factory expansion, and driven greater use of smart technologies to find additional capacity within existing production lines. “There are many reasons to be cheerful. Automotive has rebounded well after addressing supply-chain issues, and aerospace companies are enjoying their largest order books ever. Despite this, manufacturers are understandably cautious and looking for ways to boost agility and productivity without investing in additional assets.” www.fourjaw.com

Machinery & Manufacturing

Machinery & Manufacturing chats with Luke Appleby, who despite an early military career fraught with danger, now runs a business that helps manufacturers become risk-averse. Helping manufacturers worry less about security is how Luke Appleby describes the core business of Equilibrium Risk. And where better to learn about security than the Armed Forces? “My father was in the Coldstream Guards, so it felt like a natural progression for me after leaving school over 20 years ago,” he says. “I worked as a Section Commander as part of the Anti-Tank Platoon of the Coldstream Guards, before becoming a Platoon Sergeant with responsibility for up to 35 soldiers.” Luke saw active service in Northern Ireland and Iraq, and wanted to carry on helping protect Britain’s interests when he left the military in 2013. “I see manufacturing as the spine of our economy,” he says. “It supports so many jobs and helps Britain maintain its prominence on the global stage. When I co-founded Equilibrium Risk as a complete risk-based solutions provider, I felt we should focus on the manufacturing sector.” Luke describes the early years of Equilibrium Risk as “a whirlwind of learning”, but today the company is a leader in the provision of property, personal and cyber protection for all types of UK manufacturing businesses. “A manufacturer is only as secure as its weakest link, be that physical assets, staff or cyber The Career Files A risk-averse approach Luke Appleby, Equilibrium Risk

systems, so we set about improving the security posture of manufacturers while saving them time and money,” says Luke, who is a member of the Institute of Strategic Risk Management. “Our five- layer method [assess, protect, detect, respond, recover] creates a security package tailored to the customer, where the strengths of one security layer overlap the weaknesses of the next.” Equilibrium Risk is today an award-winning security and risk management company that can boast a number of successes across the manufacturing industry, particularly those that are automating their processes. And it’s easy to get started. “We provide a free security review to help manufacturers find the most efficient, cost- effective way of protecting their business while achieving a return on their investment,” he concludes. n “When I co-founded Equilibrium Risk as a complete risk- based solutions provider, I felt we should focus on the manufacturing sector”

www.equilibriumrisk.com

Machinery & Manufacturing 12

REVO uses synchronised head and machine motion when scanning, rapidly following changes in part geometry without introducing its own dynamic errors. This advanced capability paired with the exceptional performance, highest accuracy and solid upgrade path offered by Mitutoyo CMMs is an exceptional solution for manufacturers dedicated to the highest standards. Infinite possibilities with 5-axis measurement technology!

Scan here to discover more about 5-axis measurement or visit: www.mitutoyo.co.uk/5axis

CNC machining

A NEW DAWN

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CNC machining

The Norton name is synonymous with the golden age of British motorcycling that ran from the end of the 19th century to the second decade of the 21st. It’s a history that takes in Grand Prix wins in the 1930s to World Championships in the 50s. It includes innovations like the featherbed frame and the world’s first production ‘superbike’ that was unveiled at the 1967 Earls Court Motor Show. Alas, the decline of British motorbike manufacturing led the company to the brink of bankruptcy and it was only the intervention of Indian motorbike manufacturing giant, TVS, that saved it in 2020. TVS is renowned for producing quality bikes at affordable prices, but the new owner’s aim for Norton was very different and centred on making the brand its flagship, luxury line. “TVS make three million bikes every year in their Indian facilities, so they know manufacturing and they know how to make a product that is so reliable they can offer a 30,000-mile warranty on a 100cc bike,” says Adam Green, Senior Manufacturing Process Engineer at Norton Motorcycles. “Norton is a very different proposition for them. Norton is premium brand for TVS and as an owner, they want flawless paintwork, flawless polishing, reliability, component testing, the lot. Our brief is simple, make the finest bikes Norton have ever made.” TVS’ plans for the brand have included the opening of a new manufacturing facility in Solihull, West Midlands, that aims to build British bikes using a combination of traditional hand-crafted ways of working with modern manufacturing techniques to deliver consistently high quality. That willingness to embrace new ways of working led the company to critically examine how it made its bike frames in its fabricating facility. “Previously, we’d been hand-bending and hand- scalloping the bike frames because we didn’t know how to do anything different,” says Adam. “We could get the casts pre-machined but that would mean we had the welders controlling the tolerances. It’s difficult to hold a tight dimension while the component is moving around

One of the great names in British motorcycling is rising again under new ownership and with new state-of-the-art machining technology.

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CNC machining

their goals. Now, when the shopfloor receives a frame, the repeatability is going to be much better.” The new machine will be housed in a state- of-the-art production facility that is also home to the company’s new global design and R&D hub. It forms a key part of Norton’s strategic growth plan on its journey to becoming a leading player in luxury and high-performance motorcycles. At the heart of the new facility lie rigorous quality controls. “When I came here production was in a Grade 2 listed building and fabrication was in a shed. Now, bikes won’t leave factory unless everything is perfect even down to paint defects or slight scratches. If we find anything it goes back to be reworked.” “The core purpose remains frame machining, but we have been able to also introduce detail parts onto the machine as well, such as swing arms that are billeted from aluminium. The VTC is more than capable.” The Mazak has had an almost revolutionary effect on Norton’s productivity and the company’s ability to service bikes once they leave the factory. “We’ve been able to massively take out production time. Previously with all the checking and adjusting we were really only able to make small numbers. With the Mazak and the pre- welding, we think we can do 30 per day and with more accuracy.” “The Mazak has transformed what we are doing but it’s important we don’t lose sight of our heritage and our traditions. We build-to-order and our focus will always be on quality rather than output. The Mazak has been crucial in helping us blend old manufacturing techniques with new ones, keeping our traditions whilst moving into the 21st Century.” n

with all the variances, from the skill of the welder to the time of year.” The TVS takeover gave Norton much greater access to technical input which was invaluable when the company began planning for potential new motorbikes. “One idea is a cast frame and, instead of welding detailed components into the frame, we could machine the details into the casting which gives us much higher tolerances.” Norton’s commitment to only using the highest quality equipment led them to Yamazaki Mazak. “We looked at various options, but we wanted to be seen to be investing in the best available machine,” says Adam. “Mazak are the kind of people we want to be doing business with.” Norton specified a VTC 800/30SLR, manufactured in nearby Worcester, which has a high capacity working area and a wide door opening making it ideal for larger workpieces, such as motorbike frames. “The size of the frame meant we needed a big machine, but also one that could work to very high tolerances. It’s all about repeatability. The machine takes away manual process. Now every single dimension will be within 0.2 mm of each other. We’ve tightened tolerances up by 80% whereas previously there was 6 mm of difference at times from one frame to another.” Adam continues: “The shopfloor is my customer. We can measure everything to microns in temperature-controlled facilities. Nothing is going to assembly now unless it is right. I have to give them a good pass to ensure they can meet

www.mazakeu.co.uk nortonmotorcycles.com

Machinery & Manufacturing 16

Talking Tech: Micro machining

Technical Editor Steed Webzell chats all things micro machining with Greg Johnson, Product Marketing Manager and Paul Fitton, UK Sales Manager at one of the world’s leading cutting-tool suppliers in this segment: OSG UK Ltd Micro tools with macro benefits

Micro machining is an extremely broad term that makes definition open to interpretation. OSG UK has a wide variety of options aimed at this market with milling tools starting at 0.10mm diameter, taps available off the shelf at M1 and drills as small as 0.7mm diameter with through-coolant, and down to 0.02mm diameter without. The company can also supply a 1mm drill with up to 30xD capability. The mind boggles. “We work in sectors such as watchmaking where you can’t actually see the tap going into or out of the hole,” says Product Marketing Manager Greg Johnson. “It can be a little scary for our clients at first, but with the right tool and production process, it’s perfectly feasible.”

The applications for micro machining are wide-ranging. In the UK, the semiconductor sector is currently very strong, driven by major industry players in line with growing demand for AI-enabled technologies. These advanced semiconductors find their way into products such as communication devices, electric and autonomous vehicles, robotics, healthcare equipment, military technology, quantum and cloud computing systems, and a number of everyday consumer devices. Mould and die tooling, medical implements, electronic enclosures and civil/military aerospace parts are all seeing an increase in demand for smaller diameter componentry and even smaller

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Talking Tech: Micro machining

tolerance allowances. “All of these applications require technologies in smaller form factors, thus providing manufacturers with new problems in the planning stages,” says Greg Johnson. “The task for OSG is to offer cutting tools that are capable of enduring long cycle times without compromising surface finish, dimensional accuracy or tool life. All too often we hear people speak about the cost of manufacturing in this modern age and for us it’s all about tool accuracy and repeatability. For these applications, the tool must be accurate and sufficiently strong to withstand the challenging operations, but efficient enough to produce parts in a lead time that meets expectations.” For many years now OSG has been supporting customers in the micro-manufacturing arena with products such as its WXL and WXS series end mills, which are available in diameters from 0.1mm upwards and prove popular for machining hardened materials. A recent expansion to the portfolio is the introduction of the AE ranges, which utilise OSG’s latest technology to add further support for ferrous and non-ferrous materials. In all instances, the use of high-quality carbide is paramount, which is why the company has invested heavily in its R&D resources. OSG’s in-house R&D team develops numerous patented technologies, including coatings, ensuring customers can be 100% confident in the deployment of the company’s proprietary cutting- tool solutions. This ethos of self-sufficiency dates back to the origins of OSG in 1938, when the company began making its name as a manufacturer of thread- making solutions. Over the years the business has grown exponentially in both physical size and ambition, delivering cutting-tool breakthroughs in a range of application areas. OSG’s operations currently span 33 countries. It holds the number one position in the Japanese cutting-tool market, as well as a top ranking globally.

Expanding the range dramatically over the past three years, micro mills from OSG today come in a variety of form factors, including ball- nose end mills, as straight and tapered cutters. The company will have a dedicated micro-tools catalogue available in 2024 showcasing even more options. Regarding support, the company employs six area managers covering every region of the UK, all highly skilled, time-served engineers who provide advice on tools and assist with process planning. Further support comes from OSG UK’s dedicated Technical Department in Basildon. The company has numerous manufacturing facilities located in Japan, the EU and the UK. As a point of note, in early 2024 OSG will embellish its flagship Nuneaton branch with a high- specification, Walter micro-grinding machine. “Sited in a temperature controlled environment for tolerance and repeatability, the new machine will enable us to make any special micro tool below 3mm diameter, which not many in UK can offer,” explains UK Sales Manager Paul Fitton. “If UK customers need a quick turnaround on a special tool, we are investing accordingly.” OSG is clearly not interested in selling cheap tools that lack performance. Instead, the company provides premium ‘solutions’ with demonstrable productivity and quality advantages. “We believe in our products and their ability to save money for customers,” concludes Paul Fitton. n

uk.osgeurope.com

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Manufacturing solutions

Storage and Sawing- The Holistic Solution

KASTO, the manufacturer of automated warehouses for storing and retrieving raw material, both long stock and sheet, and which also produces sawing machines for cutting it to size, has been enhancing the connectivity and operational efficiency of its equipment.

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Manufacturing solutions

Whether it is a stockholder or a manufacturing facility using the storage systems and/or sawing machines, they benefit not only from higher productivity but also lower running costs through more economical use of electrical power. As an added bonus, more data is available to drive end- to-end decision-making, from order to delivery. Manually executed processes no longer meet today’s standards in the metal processing industry. Customers are offered sustainable concepts for automating and interconnecting operating sequences, from the raw material to picking the cut pieces. Processes include storage and retrieval, in-plant material handling, sawing, parts removal, marking, palletising and bundling. Solutions from KASTO ensure continuously controlled, intelligent material flow. Machines, systems, goods and load carriers communicate autonomously, enabling flexible, resource efficient, economical storage and fabrication. In this way, users remain competitive despite the rising costs of energy and materials, while at the same time improving their ecological performance. Digitisation and resource conservation are key components in the portfolio of the Achern-

based company, which has a subsidiary in Milton Keynes serving Britain and Ireland. KASTOlogic is a modular warehouse management system (WMS) designed for bar and sheet metal storage requirements. The software enables users to manage and monitor not only the processes in the warehouse itself, but also upstream and downstream processes. Even manually operated storage areas can be integrated into the system using the mobile app. All procedures such as storage and stock transfers, order picking, shipping and inventory data can be transferred to the WMS via a smartphone or tablet. The app can also be used to implement pick-by-crane systems, whereby the user commissions an integrated overhead crane that moves automatically to the storage location to source the required material. KASTO can plan, simulate and commission storage systems by combining KASTOlogic with a 3D software platform. For instance, it enables the utilisation of a configurator to create live presentations and system simulations for customers. Furthermore, project planning is faster, more accurate and leads to lower costs

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Manufacturing solutions

and higher performance, especially with virtual commissioning of fully automated storage and sawing systems. KASTOenergysave is an energy recovery concept developed for automated storage systems. It enables excess potential or kinetic energy to be converted into electrical power, which is stored in double-layer capacitors for later use. An intelligent control automatically saves and discharges the energy depending on the process that is running. In this way, users can reduce the power consumption of a gantry crane by more than 50 per cent. Energy storage can also reduce peak load, saving further costs. During sawing operations, users face the challenge of making best use of stock and avoiding waste to lower material consumption and costs. The KASTOoptisaw software module optimises the assignment of long stock to every cutting order, taking into account the parameters of the various sawing machines. Bar, tube and profile of various lengths and with different mitre angles can be cut with minimum waste, reducing costs and saving space in the store, as remnants often no longer need to be returned to storage.

The KASTOapp provides a status overview of all sawing machines in the system. If a saw is operating in automatic mode, the software can extract information from the respective machine control. The user has access to precise data on parameters such as article description, cut piece length, target and actual quantity, as well as blade cutting speed and downfeed rate. If an error occurs, a message is transmitted to allow the user to react quickly and avoid downtime. KASTO’s RemoteAssistance service delivers a high degree of availability. A direct connection enables fast, detailed, remote fault diagnosis by a KASTO engineer, even in the case of complex situations. Technicians quickly respond to questions about the operation of a piece of equipment or network, then check and change parameters, and implement software updates and upgrades. With its VisualAssistance system, KASTO takes it a step further by harnessing augmented reality to simplify the remote maintenance of machines and systems by customer personnel. n

www.kasto.com

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THE FUTURE IS HERE MV INSERTS A complete coating technology for TURNING and MILLING grades that sets new standards for tool life. . UNPRECEDENTED CUTTING SPEEDS . HIGHLY RESISTANT TO THERMAL SHOCKS . OUTSTANDING WEAR RESISTANCE . HUGE RANGE OF APPLICATIONS . CLASS LEADING TOOL LIFE

(Al,Ti)N coating

The combination of atoms with different sizes creates an exceptionally hard crystal coating structure.

mmc-carbide.com

From the Shed to the Sky Tooling technology Ritchie Engineering Solutions, based in North Essex, is a family business which prides itself on bespoke engineering product design and manufacturing quality items. Run by brothers Duncan Ritchie and Alasdair Ritchie, the company has a strong ethos for precision engineering which feeds into everything they design and produce.

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Tooling technology

A concept-to-cart company which now produces parts for Motorsport, automotive and aerospace industries, Ritchie Engineering Solutions came from humble beginnings. Back in the 1980s, Duncan and Alasdair’s father left his full-time job to follow his passion: producing steam launch engines. From the shed in the back garden, Ritchie worked alongside one other employee John Riffel, to build his business. During this time of manufacturing steam engines and steam plant, Ritchie’s thermodynamic and mechanical engineering expertise lead him to be invited to work on Richard Branson’s hot air balloon in the mid 1980s. Ritchie was tasked to produce the high altitude propane burners and capsule pressurisation equipment, which would fly the balloon from the US to the UK. A world’s first! The balloon successfully completed its journey thanks to the work and innovation of craftsmen and engineers throughout the country, including Ritchie. After the passing of his father, Duncan and Alasdair decided to carry on the legacy of Ritchie Engineering Solutions. Still running from the shed in his mother’s garden, they managed to squeeze in a CNC Lathe and 4axis CNC mill, and from this business began to steadily grow. Alasdair, who had in the meantime completed a degree in engineering design, left his full-time job to team up with Duncan 8 years ago, and since then the brothers have built up Ritchie Engineering into a successful business. Moving on from their mother’s shed, the brothers now have premises in North Essex where they currently have 9 dedicated employees and have invested more than £1.2m in the company. On the road to becoming what is now a much larger operation, Ritchie Engineering Solutions made contact with Ceratizit UK for guidance with machine inserts and tooling. Adam Cross, Technical Sales Engineer for Ceratizit UK, first started visiting

Ritchie Engineering in 2015. Having first started visiting Ritchie Engineering Solutions in the days where they were still based in a shed, Adam has been a constant source of technical support to the brothers. Once Ritchie moved to their new premises and invested in more machines, Adam helped them to solve problems as they arose and worked with the engineers to optimise their processes in order to make profit from what they were producing. Duncan commented how ‘Working with Adam has been invaluable and has been integral to our journey. He never just sells us tools; he solves problems for us and helps us to improve our processes. Working with him has given us the confidence to quote on jobs and be more competitive in the engineering industry. “Their tooling is now an integral part of our everyday machining, so having parts on demand is brilliant for us.”

25 Machinery & Manufacturing

Tooling technology

He is always at the end of the phone, and we’ve never had any problem contacting him if we need him. We really can’t sing high enough praises of him or thank him enough for what he has supported us to achieve.’ Adam visits Ritchie Engineering Solutions on a regular basis and has a constant line of communication with the brothers. Aside from Adam’s support, Ceratizit’s tooling has had a huge impact on the costs and operations in the workshop. On the Matsuura machine, which is running 24/7 in the workshop, Ceratizit’s inserts have more than doubled the tool life than the ones which were previously used, which has equated to a considerable saving in tooling costs. The MaxiMill SX indexable Parting Off tool from Ceratizit has been a standout product for the company, as the reliability of this part has meant that they have been able to run more single operation jobs and conduct more lights out running. This has allowed products to be manufactured much quicker and with considerably less scrap from damaged parts. Alasdair explained that ‘Investing in Ceratizit’s tooling has always been worth it for us, as investment in quality tooling achieves a longer tool lifetime and more reliability, which in the long run saves you a lot of money. They have a holistic view to tooling in this way, it’s never just about them making a profit, everything they recommend to you is done with consideration for your own processes and the profitability of these.’ Like many companies who work in partnership with Ceratizit, Ritchie have a Ceratizit vending machine in the workshop so that inserts and tools can be accessed immediately. Duncan described how ‘there are two practical elements to have the vending machine here. Firstly, it means that there is a robust supply chain, and secondly that we have spares available when we need them. Their tooling is now an integral part of our everyday

machining, so having parts on demand is brilliant for us.’ Ritchie Engineering, with Adam’s support over the years, have grown into a business which is able to retain competitiveness whilst not compromising on the quality of what they produce. This ethos for quality, which has been passed down by their father, lies at the heart of Ritchie Engineering. True to the heritage of where the business began, they still produce parts for hot air balloons, although these have advanced since their original designs from the 1980s! Alasdair and Duncan are looking to the future of Ritchie Engineering Solutions optimistically and are excited to see what is in store for the company in the coming years. Duncan commented that ‘We are excited to see what’s to come for Ritchie. The constantly evolving tool range from Ceratizit means that we can improve our processes as and when appropriate tools and associated cutting strategies are recommended to us.’ Whilst they are now working towards achieving more accreditations in aerospace, more of their bespoke designs are bound to be in the skies in coming years. n

www.ceratizit.com

Machinery & Manufacturing 26

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SINCE 1984

Grinding

Machining consumable spend must be reduced Myth, Revolution or Solution?

Machinery & Manufacturing 28

Grinding

The Myth Whilst it’s understandable that consumable cost is often a target for cost reduction, endeavouring to reduce consumable spend, in a world clamouring for best practice are we ignoring the obvious, does the result justify the effort? With modern grinding machines costing anything up to a million pounds, productivity or O.E.E. (Overall Effective Equipment) of machinery and manpower can deliver multiple times the total consumable cost. Assuming the cost for a machine, labour and overhead is £150 an hour, how does this compare to the consumable cost per hour? In recent tests using the latest generation of Viper wheels, Tyrolit were able to decrease cycle time by as much as 30%. Considering consumable unit costs at approximately £25 each (Viper wheel) and machine platform at £150* per hour, a 30% time saving reduction = £45; outweighing the cost of the consumable in one hour! Tyrolits Machine Tool Revolution Modular Assistance System Toolscope – Tyrolit’s Modular Assistance System; a revolutionary retrofit for any machine tool digitalisation of grinding technology. The system creates measurable added value for customers through increased process transparency featuring numerous process options, such as: O.E.E, collision detection, condition monitoring and much more. This provides an window into machining practice and process. Each machine can be set up with minimum effort, within a very short time and subsequently allows customers to save costs and time, as well as to ensure constant process quality reducing scrap, downtime and ultimately cost. The Solution! Viper Ultra Ultras Ceramic Hybrid Wheel As Tyrolit celebrates 25 years of partnership in

the development of the Viper Grinding Wheel, the development and introduction of a third generation of grinding wheels is a complete game changer. The original orange Viper wheel, lovingly referred to as “The House Brick” was superseded in 2007 by Viper Ultra; Utilising Tyrolit’s Bond Technology with a super tough but cool cutting abrasive, a new revision of the Viper Ultra was produced, now clearly identified by its blue colouring. A malleable product which adapts well to most Aerospace applications and can be found in most of the world’s machining facilities. Tyrolit UK’s latest offering, a Viper Ultra Ceramic Hybrid wheel, uses our own manufactured ceramic blend but retains Tyrolit’s Bond Technology from its predecessors. Having only been on the market for 18 months, the results, its performance and the feedback from customers have been outstanding.

The Added Bonus ? Environmentally Friendly

Tyrolit’s Ultra Hybrid wheel is manufactured at lower kiln temperatures than previous products, contains no naphthalene and with less dressing and more parts per wheel, reduces landfill, freight (Co2) as well as reducing demand for virgin material, safeguarding supply and reducing environmental impact. n

www.tyrolit.co.uk

Machinery & Manufacturing 29

EDM

The right tool for the job

As a small subcontract toolmaking and machining business, Precision Engineering Services Ltd has carved a niche in the production of press and mould tools for the construction and DIY sectors. Producing everything from CNC machining and subcontract wiring of press and mould tools to

maintaining and repairing precision tools for its clients, the Derbyshire business undertakes a significant amount of wire EDM work – this is why it has just invested in a Mitsubishi MV1200S wire EDM machine from the Engineering Technology Group (ETG).

The Buxton-based manufacturer has a selection of manual and CNC machine tools as well as a die-sink EDM machine and a wire EDM. However, with the company’s 12-year-old Mitsubishi BA8 wire EDM being the busiest machine in the company, its precision levels were sadly diminishing after more than a decade of non-stop operation. It was time for a replacement. As the Managing Director who has taken over the family business he has worked at for almost 30 years, Chris Barlow says: “Our Mitsubishi BA8 wire EDM has worked fantastically well since the day we bought it. However, after more than 10 years of non-stop running, the ball screws were deteriorating and maintaining precision

was becoming more of a challenge. We knew the machine ‘inside out’, so we could build in tolerance errors to maintain precision – but we knew that a new machine would be the best route forward. With linear drive technology and Tubular Shaft Motors instead of ball screws, the new MV1200S has a 12-year accuracy warranty and an Optical Drive System (ODS) that provides circular accuracy within 1μm, so we won’t have this concern in the future.” The toolmaker took delivery of the new Mitsubishi MV1200S wire EDM machine in May, which replaced the previous Mitsubishi BA8. Alluding to why the company once again opted for a Mitsubishi EDM machine, Chris continues: “The Mitsubishi BA8 was a brilliant machine and

Machinery & Manufacturing 30

EDM

if we had room for both, we would have kept it. When it came to picking a machine, we didn’t review the market as we knew that Mitsubishi was the best fit for our business. We did our due diligence when we bought the Mitsubishi BA8, moving from another brand to Mitsubishi. After a decade of highly productive precision machining with the BA8 - we have complete confidence in the Mitsubishi brand. Furthermore, we have familiarity with the Mitsubishi platform and transferring all our programs to the new machine was a seamless exercise.” The installation of the new Mitsubishi MV1200S and its commissioning proved a stress-free transition with minimum disruption to Precision Engineering Services. As Chris continues: “Migrating our programs to the new machine was very easy. We could either edit the NC files on the machine control or we could run the programs through our EdgeCAM software, delete our old power files, select new processing

parameters and re-run through the post- processors. This meant it only took five minutes to alter each of our legacy programs whenever a repeat job arrived.” With the majority of programming done offline in the office with EdgeCAM, Precision Engineering Services is yet to yield the full benefits of programming on the Mitsubishi control system. As Chris continues: “Whilst our programming is still completed offline, there is a huge difference with the new Mitsubishi control panel, as it has the new intelligent D-CUBES control. The large touchscreen control is user- friendly and intuitive, and we now spend less time scrolling through option menus – everything is right there on the screen. The PC is also far more powerful and faster. The previous BA8 machine could take 15 to 20 minutes to set up for every different process, the MV1200S takes less than 10 minutes. This 5 to 10-minute saving may be small, but if you have to re-set the machine

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