PES Media Production Engineering Solutions November 2023 pesmedia.com Near net shape parts from Wallwork’s new HIP Centre Pages 42-43 h f Pressing ahead Machined Components: pages 40-41 & pages 44-47 Gears: pages 48-49 Medical: page 50 SUBCONTRACTING SOLUTIONS ukmfgnews Photo credit: Adrian Waine, Photography for Industry
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www.pesmedia.com Production Engineering Solutions November 2023 3 With a number of things getting in the way – not least a pandemic – the journey to EMO 2023 was the first time I’d boarded a plane since the last event in 2019. For me, if I’m being entirely honest, EMO is one of those shows that I don’t exactly look forward to – mainly because of the ridiculous amount of walking I know I’ll have to undertake – but once I’ve been I’m always glad I went. EMO 2023 was no different. Despite walking about 25 miles during the three-and-a-half-day duration I was there, it was a fantastic show. In terms of actual real estate, a slightly smaller footprint than 2019 – but plenty of cutting-edge technology gracing the aisles; upbeat exhibitors and visitors; and encouragingly, lots of UK representation, so a really good networking opportunity. Not surprisingly, there was a big emphasis this year on digitalisation, automation and sustainability. Here in the UK, we’re all more than mindful of the devastating skills shortage that’s blighting our industry, but when you attend a show like EMO you realise that this is a truly global problem. In fact, data released post-show from the event organiser reveals that over a third of visitors cited this as a key issue for their respective businesses which is why automation was such a key theme with several hundred robots doing their thing on exhibitor stands. The future of sustainability was also high on the agenda for 68% of visitors. These are becoming very real issues that manufacturers care about passionately. Similarly, almost a quarter said that digitalisation, connectivity and networking were key priorities. For sheer international appeal, I can’t think of a better show than EMO. Around 1,850 exhibitors set out their stalls with approximately 70% coming from 45 different countries. 92,000 visitors made the pilgrimage to Hannover with 54% doing so from 130 countries. It remains an absolutely pivotal exhibition for the entire global manufacturing community – and if you can’t wait to do it all again, you’ll need to put 22-27 September 2025 in your diary. This one will be a bit of a milestone for EMO Hannover however as it’ll mark 50 years since the first event in 1975. Before I sign off, a quick word about this month’s cover story. I’ve visited many, many subcontract engineering companies in the UK over the years but few as specialised as Wallwork – the largest independent heat treatment/coatings company in the UK. I always like finding out about subjects I know little about, so I really enjoyed this one. Despite operating across multiple sites in the UK with a turnover of £30 million, the Wallwork Group remains a family business. It’s not afraid to invest either – £20m planned over the next five years including a Hot Isostatic Pressing (HIP) Centre opened recently at its headquarters in Bury. Read all about it on pages 42-43. Dave Tudor Editorial Director Representing half of a planned £20m investment program over the next five years, Wallwork Group’s brand spanking new Hot Isostatic Pressing (HIP) Centre, recently opened at its Bury, Manchester headquarters, is truly state-of-the art. Dave Tudor met up with group director Simeon Collins recently for a closer look at the new arrival and the company’s range of services from a wider perspective. See pages 42-43 Cover story COMMENT/CONTENTS year and is distributed free of charge to applicants in the UK meeting the publisher’s criteria. Subscriptions are also available at £80 per annum to UK readers or £148 overseas. Whilst every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they may arise. Authors’ opinions do not necessarily reflect those of the publisher. All rights reserved. No part of this publication may be reproduced or transmitted without the consent of the publisher. © MIT Publishing Limited 2023 You can now view your copy of Production Engineering Solutions online. To register, please go to www.pesmedia.com Contents PES has strict circulation terms of control. These are independently verified and audited by the ‘Audit Bureau of Circulations’. Circulation Statement Published by: MIT Publishing Limited, Featherstone House, 375 High Street, Rochester, Kent ME1 1DA Tel: 01634 830566 Volume 27 Issue 330 ISSN 1460-3926 EVENTS January 2024 TCT Japan Tokyo Big Sight, Japan 31 Jan - 2 Feb 2024 February 2024 Southern Manufacturing 2024 Farnborough, UK 6-8 February 2024 April 2024 MACH 2024 NEC, Birmingham, UK 15-19 April 2024 April 2024 CONTROL 2024 Stuttgart, Germany 23-26 April 2024 5 ETG grows team with prismatic expertise Ficep UK upgrades storage capacity NEWS MACHINING 16 Creating a stir weld while machining Making the most of Industry 4.0 5-AXIS 20 Haas proves to be a valuable one-stop-shop partner Branching out into 5-axis EDM 25 Sodick EDM machines help optimise part machining in battery application TOOLING 26 Getting to grips with hydraulic chucks Top tools for titanium GRINDING & SURFACE FINISHING TECHNOLOGY 28 Grinding technology that stands the test of time A wheel revolution in Viper grinding TURNING 34 ETG turns on productivity tap for subcontractor QUALITY & INSPECTION 36 Automated inspection is just what the doctor ordered TESA PMI ‘Swiss army knife’ height gauge offers consistent quality control Circulation Perception SAS Phone: 01825 701520 pes@mitpublishing.com Publisher David Rose Editorial Director Dave Tudor T: 01634 825702 newsdesk@pesmag.co.uk Deputy Editor Ed Hill T: 01634 825705 ehill@mitpublishing.co.uk Production Coordinator Ewa Hodden T: 01634 825703 ehodden@mitpublishing. co.uk Digital Content Coordinator Michael Tyrrell mtyrrell@mitpublishing. co.uk Financial Controller Valerie Prentice accounts@mitpublishing.co.uk Sales Manager Tammy Jukes T: 01634 825706 tjukes@pesmag.co.uk Sales Director Andy Morley T: 01634 825701 amorley@pesmag.co.uk Contacts
TURNING CENTRES 5 AXIS DOUBLE COLUMN SUPERIOR CONTROLS MACHINING CENTRES 12 Merlin Centre • Lancaster Road • Cressex Business Park High Wycombe • Buckinghamshire • HP12 3TB • Tel: (01494) 442222 www.hurco.co.uk, sales@hurco.co.uk, service@hurco.co.uk Your partner for 5 axis machining Several configurations to suit your application Transform plane feature for 5-sided programming Simultaneous 5 axis is standard on all Hurco 5 axis machines SRTi Range • Features a swivel B axis and a rotary C axis set in the table • Maximum 5 axis capacity within a minimum footprint • Can also be used as a full-capacity 3 axis machine • Machines available ex stock VCi/VCXi Range • Cantilever design allows excellent access • Ideal for one-offs • Greater Z clearance • Entry-level and high performance models available Ui Range • Most economical 5 axis configuration • 3 model sizes and several spindle options • Easy to automate with ProCobot or Erowa options • Machines available ex stock DCX-5Si Range • For the BIGGEST of 5 axis jobs • Machines up to 4.2m in X and 2.6m travel in Y • High-speed or High-torque spindle options available • Massive rigid structure for improved accuracy
pesmedia.com Production Engineering Solutions November 2023 5 NEWS COMPANY FINDER EDITORIAL ADVERTISING 1st Machine Tool Accessories 11 Aberlink 36 Advanced Grinding Solutions 31 Bowers Group 37 Bright Engineering 46 Ceratizit UK & Ireland 52 Compass Business Finance 9 Cranden Diamond 33 Dawson Precision Components 50 Delapena 30 DF Precision Machinery 28 DK Holdings 26 Dormer Pramet 27 Filtration Service Engineering 15 Fladder 29 GM CNC 17 Grob Machine Tools 23 Haas 13 Heidenhain 19 Heller Machine Tools 21 Hurco 4 Lang-Technik 5 MACH 2024 39 MIE Solutions 40 Mills CNC 7 Mini Gears 16 Muffett Engineering Solutions 48 NCMT 18 NJ Metrology 38 Qualiturn Products 41 RK International 33 Sodi-Tech EDM 24 Southern Manufacturing 2024 35 Subcon Drilling 44 Swissmatic 34 Sykes Machines 49 Thame Workholding 20 Tyrolit 32 Wallwork Heat Treatment 47 Wealdpark 45 WH-Lead 22 XYZ Machine Tools 2 Yamazaki Mazak 8 123 Insight 6 A&M EDM 12 Adnet Precision Engineering 45 Advanced Precision Technologies 6 ALFED 10 APT Leicester 44 Aston Martin 6 BAE Systems 13 Bowers Group 38 Bridgway Global 10 Bruderer 14 Ceratizit UK & Ireland 26 CTPE 38 DF Precision Machinery 32 DK Holdings 31 Dugard 45 Engineering Technology Group 5, 34 Erodex Group 10 Ficep 5 Floyd Automatic Tooling 27 GF Machining Solutions 22, 50 Guhring 46 Haas 20 Heller Machine Tools 16 Hervé Engineering 41 HPC Services 34 HSE 14 Hurco 21 Ingold Tools 28 LK Metrology 36 MecWash 44 Mikron Tool 27 Mills CNC 23 Muffett Engineering Solutions 48 g National Manufacturing Institute Scotland (NMIS) 17, 40 NCMT 13 Omnitool 40 Renishaw 14 Rowan Precision 46 Sodi-Tech EDM 25 Starrag 9 Studer 28 TESA 37 Tooling 2000 21 Tooling Intelligence 12 Tyrolit 30 Unison 9 Wallwork 42 Yamazaki Mazak 12 NEWS i ĞâââĜ®yµljÒ µ¡¬ĜºĜÖ¬Y®ĞćĈĉĐčĎĐčČĎč The Engineering Technology Group (ETG) has employed Ian Deacon as its new prismatic product manager. ETG has created this new role as it recognises the importance of supporting manufacturers that encounter the challenges of everything from 3- to complex 5-axis machining that often requires innovative machining solutions, creative programming and machining strategies, strategic workholding technologies and even automation solutions for increasing productivity and reducing costs. The company has long been a leader in prismatic machining with its portfolio that includes Quaser, OPS Ingersoll, Chiron Group, bavius and the recently introduced Axile brand. Collectively, the brands cater for everything from simple to complex multi-axis and high-speed machining with automation. To support manufacturers in identifying the right solution for their business, Mr Deacon has been employed to share his expertise with ETG customers, streamlining their journey to the most productive and profitable solutions. Over the last 30 years, he has worked as a senior application engineer, product manager, key account project manager and sales manager for some of the most prestigious machine tool brands in the industry. He has supported the entire spectrum of the machine tool industry – from small subcontract manufacturers with simple requirements to multinational OEMs with complex turnkey projects for some of the most challenging projects in the industry. It is this expertise and understanding of customer requirements that will ensure ETG customers have the support they need to successfully navigate any machining challenges that arise. Q Engineering Technology Group www.engtechgroup.com Ian Deacon ETG grows team with prismatic expertise Scan here for more ETG articles Ficep UK has invested in its offices and stockholding capacity as a direct response to the growing demand from clients that rely on its cuttingedge machinery solutions. The company has created additional secure storage space to hold more stock by adding 44 pallet spaces incorporated into its 17,000ft² warehouse in West Yorkshire. The installation of an additional carousel system will double the holding capacity in the Ficep UK warehouse, ensuring that essential components and spare parts are readily available to meet customer requirements promptly. In addition to the warehouse expansion, Ficep UK has also created a brand-new office space, located within the warehouse, to serve as the operational hub for the company’s tooling and consumables service team. This investment reflects the business’ commitment to providing exceptional customer service. With a dedicated team working on tooling and consumables, it aims to ensure clients have easy access to the essential components and consumables needed to maintain and optimise their machinery. Richard Clark, operations director at Ficep UK commented: “This expansion gives customers further peace of mind that quality spares, tooling and consumables stock will be readily available directly from our UK premises. This helps keep downtime, caused by part requirement, to an absolute minimum. We understand the importance of meeting our customers’ needs promptly, and our investment in warehouse and office space shows our commitment to doing the best by them.” As the company continues to grow and adapt to evolving customer needs, it is also expanding its team. It has recently recruited a tooling and consumables sales coordinator to support the administrative team and to further enhance its ability to serve clients efficiently and effectively. More details about current vacancies at Ficep UK role can be found at www.ficep.co.uk/ about-us/careers. Q Ficep www.ficep.co.uk Ficep UK’s newly installed carousel system which doubles its warehouse holding capacity Ficep UK upgrades storage capacity Scan here for more Ficep articles
6 November 2023 Production Engineering Solutions pesmedia.com NEWS Aston Martin’s high-performance electrification strategy has been awarded £9m of government funding through the Advanced Propulsion Centre UK (APC), further supplementing the research and development of Aston Martin’s innovative modular battery electric vehicle (BEV) platform. Awarded following a competitive process, the Government grant will support the development of Aston Martin’s luxury BEV platform and enable a route to Net Zero, including investment in vehicle lightweighting, a digital toolchain and electrification training. Today’s funding announcement is another positive step in Aston Martin’s electrification programme, which forms a pillar of the company’s wider ‘Racing. Green.’ sustainability strategy. The innovative British ultra-luxury manufacturer is making a £2bn commitment to advanced technologies over the next five years, with its investment phasing from internal combustion engine (ICE) to BEV technology. Project Elevation, a six-partner collaborative research and development project led by Aston Martin, is supported by the Manufacturing Technology Centre, Expert Tooling & Automation, Creative Composites, Fuzzy Logic Studio and WMG, University of Warwick. The project will address the technical challenges of developing a lightweight, 800V traction battery pack and twin front electric drive unit (EDU) into a modular BEV platform with a bandwidth from supercar to SUV. Roberto Fedeli, group chief technology officer at Aston Martin, said: “The award of funding from the APC is another major boost to our electrification strategy and constant strive for innovation. It will help achieve our ambition to be an in-house BEV technology leader in the ultra-luxury, high-performance segment. We look forward to progressing this project with our collaborative partners and thank the APC for their incredible support.” Ian Constance, APC chief executive, said: “The 23rd round of our collaborative R&D competition coincides with the APC’s 10th anniversary. We’ve seen over £1.4bn of investment into automotive projects since the APC was set up, and I am proud of the impact that we have made here in the UK. “This latest announcement includes a diverse set of OEMs and suppliers that demonstrate the strength of UK automotive. They will further add to our portfolio of innovative projects and continue to drive the UK to deliver on its Net Zero ambition.” By 2026 all new Aston Martin model lines will feature an electrified powertrain option, with the long-term objective for its core range to be fully electrified by 2030. Q Aston Martin www.astonmartin.com Aston Martin wins government backing for electrification programme 123 Insight has launched V23.2 of its leading manufacturing ERP system software. The new version includes over 70 updates and improvements across all modules of the 123Insight software, including admin, commercial, planning, production, purchasing, sales, stores, reporting, performance, Software Development Kits (SDKs), exports and more. Notable new features include: O Complete redesign of the ‘Add/ Edit Company’ screen, with several changes including enhanced security control, tab level permissions, CRM changes, and the ability to add external attachments O New Despatch Analysis Codes and the ability to add external attachments O Enhancements to the Book Goods In screen O Active Directory integration for simplified user login O Several serialisation updates, including Serial Linkage for nontracked works orders O New exports to Microsoft Excel for the convenient extraction of data Bradley Debenham, director of business management at 123Insight said: “This is the second major release in six months, demonstrating that 123Insight is constantly evolving as a result of continual investment of subscription revenue back into development. Many of these enhancements are as a direct result of customer feedback.” The new release is available immediately for existing customers as part of the standard monthly subscription. Although upgrades can be performed by customers themselves, they can also opt for the software to be upgraded remotely for just £345, providing a safe, hasslefree way to immediately benefit from the latest release. Q 123 Insight www.123insight.com 123Insight manufacturing software V23.2 released A Chatteris-based engineering company has announced the appointment of a new director. 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. Mr Speirs 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. Since May, Advanced Precision Technologies has invested in a new 5-axis CMX 70U machine from DMG Mori and Open Mind hyperMILL programming software. It is also investing heavily in refurbishing its 1,486ft² premises at the South Fens Enterprise Park and working towards several key ISO accreditations which Messrs White and Speirs hope will open doors for them with major motorsport, automotive and medical equipment brands. Danny Speirs said: “Thomas has already achieved so much since establishing Advanced Precision Technologies last year, including moving into our premises in Chatteris. I’m delighted to be joining the business as a director and working together as business partners to press ahead with our exciting growth plans and really get our name out there as leaders in the manufacturing of high-performance parts.” Thomas White added: “Having previously worked with Danny, I am hugely excited to announce him as a codirector of the business. We have some exciting plans coming to fruition and he will be a massive influence in developing and steering the business towards the vision that we both share.” Q Advanced Precision Technologies www.aptechno.co.uk Thomas White (left) and Danny Speirs Cambridgeshire engineering firm appoints new director Scan here for more 123 Insight articles Scan here for more Aston Martin articles
Component manufacturers don’t think twice when it comes to investing in 5-axis machines that deliver unrivalled speed, precision, flexibility and process reliability. That helps explain why demand for our DVF 5000 machines remains so high. Equipped with 17kW/12,000rpm direct-drive spindles (22kW/18,000rpm option); 40m/min rapids; generous sized tool changers (up to 120 tools); integrated thermal compensation systems; the latest controls and an 8 pallet automatic workpiece changer option - DVF 5000 machines are helping component manufacturers improve their productivity, performance... and profitability. They could definitely do the same for you. To find out more visit www.millscnc.co.uk or call 01926 736736. Mills CNC: Like No-one Else! The DVF 5000 simultaneous 5-axis machine. It would still be a great machine with just half the features! Mills CNC Technology Campus: 01926 736736 www.millscnc.co.uk
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pesmedia.com Production Engineering Solutions November 2023 9 NEWS Thinking Differently about Finance innovative sustainable connected flexible competitive straight-forward relational simple Call us on01732 833477or visit compassbusinessfinance.co.uk Fabtech 2023, which took place in Chicago over a four-day period during September, proved to be a major success for Unison Ltd, the UK-based inventor of all-electric tube manipulation, and its North American division, Unison Tube LLC. Over the course of the event, 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’s stand to view the all-electric Unison Breeze CNC tube bender that would soon be on its way to his company. The machine purchased by Sharpe Products: a 100mm (4 inch) single-stack Breeze model, formed the centrepiece of Unison’s Fabtech display. It is the ninth Unison Breeze to be bought by Sharpe Products since 2003 and will be used to provide additional capacity for bending tubular components for the business’ extensive customer base. “We’re absolutely delighted that Sharpe Products has chosen to purchase yet another Unison Breeze all-electric tube bending machine,” said Stuart Singleton, VP of Unison Tube LLC. “As you can imagine, such impressive repeat orders are an incredible testimony to the faith a customer places in our machine tool technologies, operating software and product support.” For Unison, the Breeze 100mm (maximum tube diameter) machine is one of its flagship models. Just like all Breeze machines, it offers rapid setup, fast tooling changes, plenty of power, a rigid mechanical design, and allelectric control for right-first-time repeat subcontract work, or immediately after producing a single trial part. These are all attributes that Unison believes make its Breeze models the ultimate tube manipulation machines for businesses specialising in frequently changing, small-to-medium batch production runs. Other Fabtech highlights included the considerable interest shown in its EvBend range of manually operated, CNC-controlled 3-axis tube bending machines. Typically used for lowvolume, high-accuracy production and prototyping, Unison EvBend machines provide accurate multi-plane bending at a much lower cost than many CNC benders. Two models are currently available – the EvBend 1000 for bending tube of up to 16mm in diameter, and the EvBend 2000, a machine featuring power-assisted operation and capable of bending tube of up to 50mm in diameter. Unison EvBend machines are widely used across the aerospace and motorsport sectors for bending precision components. Q Unison www.unisonltd.com From left: Stuart Singleton, VP, Unison Tube LLC; John Nimmons, plant manager, Sharpe Products; Paul Krickeberg, CEO, Sharpe Products; and Alan Pickering, joint managing director, Unison Ltd Unison enjoys a fantastic Fabtech Scan here for more Unison articles EMO world premieres: Starrag sets new standards for compact machining Building on the successes of the existing Heckert H50/H60 and heavier duty H55/ H65/H75 4-axis machines designed for heavy machining, the recent EMO Hannover show saw Starrag unveil two world premieres – the Heckert H85 and H95 models – with pallet sizes of 800 and 1,000mm respectively. They are regarded as successor models to the successful Heckert HEC 630 and HEC 800 machining centres, which have been true mainstays of Heckert’s core business. Since 2017, Starrag has been continuously refreshing the new Heckert compact module at its Chemnitz, Germany plant. The results are impressive – topclass horizontal machining centres with renowned Heckert DNA – power, precision and flexibility. In the new compact machines, Starrag distinguishes between the H series (4-axis machining centres), the X series (5-axis machining centres) and the T series (5-axis machining centres with turning function) depending on the equipment variant. The basic modular concept of the machines already offers optimum efficiency in the standard Heckert H50 and H60 configurations. This also applies to the Heckert H55, H65 and H75 versions, which are designed for heavy machining in terms of spindle, column and tool magazine. This series now includes the brand-new H85 and H95 models with pallet sizes of 800 and 1,000mm. At EMO, the H95 was put through its paces, demonstrating its power, speed and flexibility. In Hannover, the machine was equipped with an optional 53kW/4,000rpm/2,042Nm NC quill with 500mm travel which saves tool costs and cycle times when machining deep surfaces and bores. Various machining strategies, including HPC and trochoidal milling, were demonstrated live using high-feed milling cutters, face-milling cutters and hedgehog milling cutters, as well as various drilling tools. The highly rigid, compact Heckert H95 sees Starrag improve the previous top model – the HEC 800 – even further. In fact, the company reports a 7% productivity increase when compared to its predecessor. Together with its smaller sibling, the H85, the machine has been designed from the ground up with automation and integration to existing infrastructures in mind, featuring 13 channel extended clamping hydraulics and simplified interfaces to pallet storage systems and robot cells. There are up to 450 tool locations in the tower magazine. Q Starrag www.starrag.com Scan here for more Starrag articles
10 November 2023 Production Engineering Solutions pesmedia.com NEWS Erodex, a leader in the design and manufacture of graphite electrodes, tooling and fixtures, has taken on two new apprentices within its Wednesburybased graphite machining facility. The company’s machining facility has been established for over 35 years, enabling Erodex to machine its wide variety of graphite grades into highly complex components for a range of industries. Jack Needs joins the team as an apprentice machinist, accompanied by Kane Howl who joins as an apprentice grinder. Both apprentices have embarked on a dedicated plan of learning within the Erodex machining facility as well as pursuing off the job learning at Make UK Apprenticeships and Training in Aston, Birmingham. Company director, James Kirk, commented: “The nature of our engineering is highly skilled and involves working to extremely tight tolerances. As with most engineering firms across the country, we see a shortage of skilled time served individuals that fit our profile so we accept that it is our responsibility to develop our own talent. We commit a significant amount of time to training our apprentices on the job and look forward to seeing them progress within the company. “There will be opportunities for these individuals to grow within the business moving forward as we help them to develop the required skills. Everybody at the Erodex Group wishes them the best moving forward and I am sure that they will all continue to enjoy successful careers with us.” January saw Erodex relaunch its apprenticeship scheme with the ongoing external consultancy support of Next Gen Makers, following best practice methods to ensure the apprenticeship scheme remains best in class. Erodex is pursuing accreditation for the Make UK Engineering Apprenticeships: Employer Kitemark through Next Gen Makers, which recognises excellent employers of engineering apprentices in the UK. As part of ongoing skills succession planning, the company is also taking an innovative approach to attracting the next generation towards apprenticeship opportunities, including virtual reality outreach sessions for students in local colleges. In the coming years, Erodex will be offering apprenticeships starting at level 3 in multiple disciplines, including engineering technicians and a range of other opportunities within other departments across the business. The machining facility remains a key driver in the significant growth that Erodex has experienced in recent years, receiving over £2m worth of planned investment in new machinery as part of a continuous improvement programme. Q Erodex Group www.erodex.com Erodex appoints new apprentices L-R: New apprentices Kane Howl and Jack Needs Scan here for more Erodex Group articles ALFED, the aluminium federation, has launched a new report examining the impact of the Russia/Ukraine war on the UK aluminium industry. Developed in partnership with CRU International, the document explores the short, medium and long-term consequences of government import sanctions, as well as suggesting alternative future options to maintain primary aluminium supply. With the objective of protecting the UK’s thriving aluminium supply chain, supporting domestic production and minimising the effects of geopolitical issues, the report considers how removing Russian material from imports will directly impact UK businesses, as well as how changing market dynamics will likely hit future export demand. The opportunities to increase uptake of recycled content and reduce the industry’s carbon footprint are also covered in detail, alongside the wider supply chain issues presented by a weakening global forecast. Tom Jones, chief executive officer of ALFED, commented: “Politically, and morally, pressure is increasing to ensure that all materials used within the UK have a clear path of origin and do not in any way support the Russian state. While Russian-sourced aluminium was only ever responsible for a small fraction of the import market, it is still important to consider the longer-term picture to ensure minimal disruption to the supply chain. “Our latest report investigates the widespread impact of global conflict, identifying both challenges and opportunities, but also raising a number of highly pertinent questions. Firstly, what does a viable future solution for material sourcing look like? Secondly, what support should the UK Government offer to support the wider agenda? And, finally, what are the immediate priorities that we – as an industry – must be tackling to maintain global competitiveness? “It’s fair to suggest that this report is a hugely important resource for any business involved in the UK aluminium supply chain and I’d implore industry professionals to take the time to read it in further detail. ‘Impacts to UK aluminium industry following Russia/Ukraine war’ is available for members to download via the link below on the ALFED website. Q ALFED www.alfed.org.uk https://alfed.org.uk/wp-content/ uploads/2023/10/ALFED-Russian-Alu-Report. pdf New report looks at impact of global conflict on UK aluminium industry A leading figure in the world of advanced manufacturing has joined forces with experts in innovation districts, land development and public affairs to establish a strategic advisory business that supports economic growth. Bridgway Global, headquartered in West Yorkshire, brings together three key figures – Professor Keith Ridgway, Iain Thomson and John Yates – who worked together in transforming the site of the derelict Orgreave colliery and coking works into a cluster of advanced manufacturing companies including Rolls-Royce, Boeing, McLaren, Nikken and the UKAEA. Professor Ridgway, director of Bridgway Global who leads the business on manufacturing and industrial innovation said: “An innovative and expanding manufacturing base is essential to building strong communities and a more sustainable economic future, driving big gains in productivity and turning the brilliant ideas born of fundamental science into home grown businesses, technologies and products.” A new community of more than 2,000 homes is blossoming on the old Orgreave site alongside a world-class cluster of aerospace, green energy, defence, and automotive brands and their supply chains. Fellow director and Bellona Advisors’ managing director, Iain Thomson, who leads the business on land and property development matters and public-private partnerships, added: “The wealth of knowledge and experience in the team enables us to act as a vital bridge between advanced manufacturers, land and property interests, research institutions and both national and regional government in an era of growing devolution across the world.” Bridgway’s initial service offer will provide strategic advice to major landowners and developers looking to promote new advanced manufacturing schemes and decarbonisation clusters. It will also connect advanced manufacturers to policy makers, research and development specialists and funders to improve market conditions to grow their businesses. This includes the development of industrial policy at national and regional level and the creation of public-private financial instruments. Bridgway global director John Yates, who was head of external affairs at the Advanced Manufacturing Research Centre (AMRC) when Boeing, McLaren and the UKAEA opened facilities on the campus, added: “As a small, agile business armed with a wealth of experience in all these fields, we can be the catalyst that cuts through obstacles and delay to make things happen and get things done.” Q Bridgway Global www.bridgwayglobal.co.uk AMRC co-founder launches private sector advisory business
12 November 2023 Production Engineering Solutions pesmedia.com NEWS During the 2020 coronavirus lockdown, Gary Surman of West Midlands precision engineering subcontractor A&M EDM, acted on a longstanding ambition to improve the performance of the A-series Classic Mini engine block. Mr Surman was convinced that advances in engine technology could improve the racing performance of the original engine. A&M designed and manufactured a road race version block machined from solid aluminium weighing only 20.5kg compared to the original 32kg, boosted by five functioning main bearings rather than three. Mr Surman and A&M’s managing director, Mark Wingfield then created a separate company, Ascaso Engineering to develop the engine, believing a proprietary product would assist the precision engineering subcontractor’s long-term growth. The block is machined on a Hurco VMX42Ui 5-axis VMC cutting at high feed rates up to 10m/minute. The crankshaft is produced from a solid billet using Autodesk PowerMill and the swivelling B-axis of a Hurco VMX60SRTi VMC synchronised with the motions of a Kitagawa GT320 rotary 4th axis table. Mr Surman said: “We have manufactured precision components for Formula One, aerospace, automotive and marine industries for many years and applied our engineering skills to manufacture this engine. The original had three main bearings but the new version has five, so it can rev at higher speeds up to 10,000rpm and accept a load over 350 BHP.” The A+5 1,273cc K16V turbo engine was successfully circuit tested in December by Mini racer Jim Lyons. He drove the 1,273cc Turbo version for its first race at the world’s fastest Mini event at Brands Hatch in August 2023, finishing in fifth place, overcoming a split exhaust manifold. Mr Lyons said: “The engine is outstanding. Gary and the rest of the A&M team have done a fantastic job. The quality of the machining is better than I’ve ever seen before. I can really feel the difference in the weight of the engine. The Ascaso engine has a bulletproof bottom end, so we can really start to get some serious power.” A&M has developed different capacities of dedicated classic Mini engines, from 1,071cc through to 1,400cc for the BMW K16V and 12G940 heads and anticipates sales from Mini racing enthusiasts around the world. Q A&M EDM www.amedm.co.uk Based in Warwickshire, Tooling Intelligence is a premier industrial inventory and asset management specialist that works in partnership with US business SupplyPro. Focusing on innovation and excellence, it offers cutting-edge solutions for optimised inventory management, efficiency improvement and growth. The company has recently announced a move to a new facility as part of strategic expansion plans. The relocation supports increased assembly capacity and introduces a dedicated service and support centre, better serving its growing customer base. This marks a significant milestone in delivering exceptional solutions across Europe and beyond. “We’re excited about this new chapter,” said managing director, Richard Swaffield. “The upgraded facility enhances our capabilities to serve customers better, handle larger volumes, and reach international clients.” Tooling Intelligence’s move and expansion supports its goal to revolutionise inventory management, backed by a highly successful distribution and installation partnership with San Diegoheadquartered SupplyPro. Since 2007, Tooling Intelligence has been SupplyPro’s exclusive European OEM partner with installations in over 50 countries. Floyd Miller, CEO of SupplyPro commented: “We’re thrilled about Tooling Intelligence’s relocation and operational expansion along with their commitment to delivering exceptional solutions and support. We eagerly look forward to a continuing successful partnership and future.” The new facility in Honiley aligns with Tooling Intelligence’s mission to optimise industrial inventory and asset management with advanced technologies. Q Tooling Intelligence www.toolingintelligence.co.uk Norton Motorcycles is targeting a major productivity boost following the delivery of a new Yamazaki Mazak vertical machining centre (VMC). The iconic motorcycle brand, based in Solihull in the West Midlands, has taken delivery of a Mazak VTC 800/30SLR into its fabrication facility that is capable of machining an entire bike frame within the high capacity working area. The new investment will be used to machine the fine detail onto the company’s bike frames – work that had previously required a manual process. Adam Green, senior manufacturing process engineer at Norton Motorcycles says the machine will offer a major productivity boost. He commented: “We’re planning for a new manufacturing process, so instead of welding detailed components into the frame, our intention is to machine the details into the casting which gives us much improved quality control. “Previously with all the checking and adjusting, our output was limited. With the Mazak machine’s help we think we can manufacture three or four times as much and with more accuracy. The VTC is a big machine that can work to tight tolerances and we are confident it will have a major impact on our productivity.” Norton was acquired by the Indian motorbike manufacturing giant, TVS, in 2020, a move that saved the company from the brink of bankruptcy. The machine will be housed in Norton’s production facility in Solihull that also includes a new global design and R&D hub. The VTC 800 series of machines were specifically designed for European machine tool users and are manufactured at Mazak’s only European manufacturing site in Worcester. The machine has a travelling column design with full 5-axis capability making it ideal for the machining of complex features and contours. Alan Mucklow, managing director UK, Eire and national distributors at Yamazaki Mazak, enthused: “The VTC-800/30SLR is an excellent choice for Norton’s frame machining requirements as it is a highly versatile machine capable of working with large components such as bike frames, but at the same time able to be utilised for complex detail work. “Norton Motorcycles is an iconic British manufacturing brand and we are delighted to be partnering with the company as it looks to bring advanced manufacturing techniques into its Solihull production facility.” Q Yamazaki Mazak www.mazakeu.co.uk A&M EDM’s A+5 production team Revamped Mini engine races to new heights The team at Tooling Intelligence. Managing director Richard Swaffield (centre right) is pictured alongside his father and company founder Mike Swaffield Tooling Intelligence relocates to new stateof-the-art facility Norton targets output boost with new Mazak machine Scan here for more Yamazaki Mazak articles
pesmedia.com Production Engineering Solutions November 2023 13 NEWS NEWS MADE IN USA Haas Automation | 01603 760539 | sales@haas.co.uk The world’s best selling VMC for a reason. Auto Parts Loaders | Plug & Play Robots | Integrated Pallet Pools NEW www.haas.co.uk Andy Skee has joined machine tool supplier NCMT as sales manager for the North-East of England and Scotland. The company is sole agent in the British Isles for Japanese-built Makino machining centres and EDM machines, and for Okuma machining centres, CNC lathes and grinders. It is also European agent for the photo-activated adhesive workholding systems manufactured by Blue Photon in the US. Mr Skee started his career programming and operating CNC machine tools and inspecting components for two manufacturers in the North-East. During his previous roles, he had direct experience using Okuma twin-chuck vertical machines within the machine shop at a subcontractor specialising in subsea equipment manufacture, followed by several years in a similar role within the UK Ministry of Defence. More recently, Mr Skee was a customer-facing applications engineer providing training and support covering a wide variety of machining platforms. In July this year, he completed a University of Lincoln FdSc Operations Management distance learning programme and is currently working towards a BSc in Business Management, in which he expects to graduate in Autumn 2025. Q NCMT www.ncmt.co.uk BAE Systems has secured an additional £130m of new orders for the supply of munitions to the UK Ministry of Defence (MoD). The award follows the decision by the MoD to exercise the option to increase the supply contract announced in July from £280m to £410m. The full order will be supplied via BAE Systems’ facilities in Washington, Tyne and Wear, and Glascoed, South Wales. The overall contract will create more than 200 new highly skilled jobs in the North of England and South Wales, boosting the company’s 1,200-strong UK munitions workforce. Glynn Plant, managing director of the munitions business at BAE Systems, commented: “This contract builds on our extensive relationship with the UK MOD as a strategic partner for munitions supply. Our teams are increasing production rates, investing in people and new facilities and maximising shift patterns to meet the enhanced demand while ensuring every shell meets our exceptionally high standards.” Building on the existing £2.4bn 15-year partnering agreement, the new orders will significantly increase the production of critical defence stocks of 155mm artillery shells, 30mm medium calibre rounds and 5.56mm ammunition. As well as bolstering the British Army’s heavy munitions stockpile, the orders will enhance its latest weapons systems and satisfy the increased demand for small arms ammunition. The £410m contract will also support investment including: an additional 155mm machining line in Washington, Tyne & Wear; a new explosive filling facility at Glascoed, South Wales; and re-instatement of 30mm medium calibre manufacturing capability at Washington and Glascoed. Q BAE Systems www.baesystems.com 155mm artillery shells BAE wins additional £130m munitions order Scan here for more NCMT articles Scan here for more BAE Systems articles NCMT appoints sales manager in the NorthEast and Scotland
14 November 2023 Production Engineering Solutions pesmedia.com NEWS Renishaw, a leading global supplier of measuring and manufacturing systems, has appointed a new non-executive director. Professor Karen Holford CBE FREng joined the board of directors of the FTSE 250 company on 1st September 2023, where she will contribute more than 43 years of expertise in the engineering sector. Professor Holford, who is chief executive and vice-chancellor at Cranfield University, will also join Renishaw’s audit, nomination and remuneration committees. As well as her extensive engineering, technical management and governance experience, Professor Holford has previously helped to address a lack of diversity in organisations by challenging perceptions and working with underrepresented groups. She began her engineering career at Rolls-Royce as an undergraduate apprentice, graduating from Cardiff University with a BEng (Hons) in Mechanical Engineering. She returned to academia to pursue a passion for research, gaining a PhD in Materials Science/Acoustic Emission. She then continued her interest in research and development in industry at AB Electronic Products, eventually becoming a senior engineer leading a large mechanical design team. This role gave Professor Holford hands-on experience in a variety of engineering applications. She then returned to academia, specialising in industry-led teaching, research and development and progressing to Professor of Mechanical Engineering. She served in leadership roles such as Head of School of Engineering, Pro Vice-Chancellor of Physical Sciences and Engineering, and spent five years as Deputy Vice-Chancellor of Cardiff University, before taking up her current position at Cranfield University. She is a Fellow of the Royal Academy of Engineering and was named as one of the 50 most influential women engineers in 2016. In 2017 she received a CBE for services to engineering and the advancement of women in engineering. “We are delighted to welcome Karen to the board,” said Sir David McMurtry, executive chairman at Renishaw. “She has a wealth of engineering and R&D experience, bringing vital skills to the business.” Q Renishaw www.renishaw.com A leading manufacturer of high-speed presses will open a 48,000ft2 new factory and showroom in Telford in 2024. Swiss-based Bruderer has reinforced its 55-year commitment to the UK by announcing a significant investment in the dedicated site in Hortonwood, Telford. Construction work on the bespoke facility will start in October and will see the creation of a dedicated competence centre capable of servicing new and pre-owned machines, restoration of legacy presses and, for the first time, a modern showroom that will give a firsthand insight into new models, ancillary equipment and turnkey solutions. The move will see the firm relocate its existing facility from Luton to Shropshire over the course of the next nine months, with four new jobs and an apprenticeship programme set to be created to cope with an unprecedented increase in demand for its technology. “We have been planning this investment for a number of years and I’m delighted that our parent company have recognised the potential in the UK and agreed to build our new factory and showroom,” explained Adrian Haller, managing director of Bruderer UK. “The UK was the first subsidiary outside of our Switzerland home some 55 years ago and we remain a strong base for Bruderer presses, with seven domestic companies investing in new machines in the last nine months alone.” He continued: “We had outgrown our Luton facility and many of our staff, and indeed customers, are based in the Midlands. It was a natural decision to find a home in that region and Hortonwood gave us not only the perfect location, but also the space to build our new factory from the ground up. “This means we can house all our spares, a cleaning and paint shop, machining area, quality checking station and exhibition space to promote all our solutions under one roof. Staff will also be looked after, with outside areas set in landscaped gardens, air-conditioning throughout, showers, changing rooms and EV charging.” Bruderer UK is a market leader in high precision punching technology and turnkey solutions. Thanks to several strategic partnerships with ancillary equipment providers, it also offers full turnkey solutions that include tooling, servo feeders, decoilers, multi-way rewinders, vision systems and press and tool monitoring systems. Q Bruderer www.bruderer.co.uk UK manufacturing businesses are being warned to make sure their staff are safe when working with metalworking fluids or coolants. Past inspections by the Health and Safety Executive (HSE) have uncovered poor performance around control of metalworking fluids in businesses that use CNC machines. Exposure to metalworking fluids – also referred to as ‘white water’ – can cause harm to lungs and skin through inhalation or direct contact with unprotected skin, particularly the hands, forearms and face. Breathing in the mist generated by machining can lead to lung diseases such as occupational asthma and hypersensitivity pneumonitis. Manufacturing businesses should implement control measures and carry out health surveillance checks with occupational health professionals. HSE inspector Fiona McGarry, said: “Lung problems and irritated skin don’t have to be associated with working with metalworking fluid if you take the right precautions. It is really important that control measures and fluid quality checks are in place to keep workers healthy. Health checks are essential to identify signs of ill-health early.” To support the campaign, HSE will carry out inspections to look at how employers are ensuring workers are protected from exposure to fluid or mist generated by machines across Great Britain. Britain’s workplace regulator plans to carry out unannounced inspections between now and March 2024. Local exhaust ventilation (LEV) should be fitted on CNC machines to carry away any harmful metalworking fluid mist, which is difficult to see in normal lighting. Fluid quality should be regularly checked focusing on concentration, pH, bacteria and contaminants. Fluid systems can become highly contaminated with harmful bacteria. Where there is exposure to fluid or mist, it is a legal requirement to carry out health surveillance even when preventative controls are in place. You will need to involve an occupational health professional and workers should be encouraged to report any health symptoms that occur. Q HSE www.hse.gov.uk Bruderer to open new factory in Telford next year Scan here for more Bruderer articles Scan here for more Renishaw articles Dangers of metalworking fluids highlighted in HSE campaign Renishaw expands leadership with new non-executive director
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