Winbro machine accelerates EDM drilling

For manufacturers that need to produce holes and features in challenging materials and components, EDM drilling is often the only feasible solution when precision and workpiece integrity is critical. The Engineering Technology Group (ETG) is introducing the Winbro HSD6-GT high-speed EDM drilling system to accommodate such exacting demands on large components.

Winbro’s HSD6-GT has been developed from the original Winbro HSD6 platform to take advantage of the latest design, control and process concepts employed in high-speed EDM for large annular components with a weight capacity of up to 500 kg. To accommodate heavy-duty parts, the Winbro HSD6-GT provides travels of 1050 x 540 x 720 mm in the X, Y and Z linear axes. To enable single-set up and drilling on all faces of the component, the machine also has a rotary A axis of +210°/-60°, a B axis of +100°/-200° and a continuous C axis.

The next-generation Winbro HSD6-GT demonstrates linear and rotary accuracy of 0.015 mm and 0.007° respectively, while linear repeatability is 0.01 mm and rotary repeatability is 0.003°. This level of precision is courtesy of several integrated innovations, such as the patented six-point probing system and optical on-machine inspection.

The six-point probing system ensures accurate positioning of the component before drilling and allows precision positioning using simple fixtures. Complementing this feature is a laser opticator that provides complete optical on-machine inspection to guarantee accurate hole positioning. Whilst the laser opticator and six-point probing system underpins the precision performance of the Winbro HSD6-GT, the integrated signature analysis system monitors drilling performance in real-time to reduce the requirement for manual inspection.

Winbro’s HSD6-GT can create holes from 0.3 to 25 mm diameter, and up to 100 mm deep.

For further information
www.engtechgroup.com

Magnetics can improve EDM filtration

Even with its precision and high-quality results, EDM can – and often does – come with its problems. Until recently, solutions to such issues have been difficult to come by. However, with the help of magnetic technology, many problems can be overcome, increasing machine efficiency significantly.

Properly filtered dielectric fluid is instrumental in producing highly accurate and high-quality machined parts, and is essential for transferring the charge during the process, flushing particles out of the gap between the workpiece to prevent them from forming bridges that cause a short circuit.

By using a magnetic filter in conjunction with the traditional paper barrier filter, fluids benefit from the highest level of protection. Using a paper filter alone can allow particles smaller than the pore of the filter to flow through, leaving the fluid susceptible to secondary sparking. By introducing magnetic technology, it is possible to quickly and safely remove these particles, ensuring the removal of virtually all contamination.

The Micromag magnetic filter, designed and manufactured by Eclipse Magnetics, provides a way of solving many problems that occur during the EDM process. Its high-intensity collection capabilities, coupled with its high-strength magnetic core and an optimised fluid flow orientation, work to remove almost all ferrous particles from the dielectric fluid. Cleaner fluids lead to marked improvements in secondary sparking, significantly less wire breakages, increased machine productivity and longer tool life.

According to Eclipse Magnetics, Micromag provides a rapid return on investment – often within just weeks – and, with its easy-clean design, the collected swarf can be quickly and efficiently disposed of and recycled, reducing the need for high-cost consumables.

For further information
www.eclipsemagnetics.com

Abbey reduces cutting-fluid costs with Rocol

Like many subcontract manufacturers, Abbey Tool and Gauge Ltd was started by a husband-and-wife couple out of a small shed near Kelso Abbey – hence the name. The ethos of the subcontracting company since it opened its doors in 1970, has been to buy the best- possible equipment and machine tools. In its 50 years, this has seen the company invest in numerous Nakamura-Tome, Doosan and DMG Mori machines with a spend of more than £6m in the past five years on five- through to nine-axis machines for one-hit machining.

Under the management of second-generation brothers Iain and Alistair Reid, the subcontract company has expanded its portfolio, now working in the oil and gas, nuclear, automation, and medical industries. The ISO9001 and ISO14001-certified manufacturer implements a programme of continuous improvement that not only encompasses machine tools, but also complementary technology. This is why Abbey Tool and Gauge has invested in cutting fluid from Rocol.

Taking up the reasoning behind switching its fluid provider, Abbey Tool and Gauge director Iain Reid says: “At first, we were a little sceptical when Rocol came in to see us because they said they could run our oil consumption at 2%, and we were running at somewhere between 6 and 8%. Alistair and I thought long and hard about it, and we filled two machines with the product. We ran these machines for six weeks and were delighted.

“This change is good for the environment as it is only running at 2%,” he continues. “It will also be good financially for our business in the long term as there will be a big saving, which we are monitoring at the moment. Thirdly, the back-up and support we’ve had from the Rocol team have been absolutely phenomenal.”

Since implementing Rocol Ultracut 370EP, the benefits have cascaded throughout the business. Alluding to machining performance, Reid says: “We’ve had some really good feedback from the guys on the shop floor. We were initially concerned as we machine a lot of super duplex and thought that the Rocol Ultracut 370EP wasn’t going to do the business there, but it certainly has. It has also been a huge success on materials like Inconel, 625, 718 and many others.”

The Roxburghshire facility in Scotland is home to more than 30 machines and, despite the volume of machine tools, the facility is completely odour free.

“It’s quite incredible because the odour disappeared almost immediately,” says Reid. “A Rocol engineer comes in every couple of weeks and tells us where we are with regards to our coolant management. So, the fluid is managed to a very high standard.”

Rocol Ultracut 370EP is free from bactericide, silicone, chlorine, formaldehyde, nitrites and any animal-derived materials, prolonging fluid life and performance. Additionally, the low-foaming product is compatible with hard and soft water, and is tolerant to tramp oil and demonstrates protection against residual corrosion.

Trying to quantify the savings since instigating the change of cutting-fluid supplier to Rocol, Reid says: “I think the savings could be anything from £20,000 to £40,000, but as we’ve not been using the Rocol fluid for a full 12-month period, we cannot give an exact calculation at present.”

Referring to the impact Rocol has made on tool life and performance, he says: “Looking at our historical usage, we estimate that we’ve already saved between 10 and 12% on our cutting-tool costs, which is massive in our game. In some cases, we slow the machines down to reduce the tip changes. We find it’s better to run the machines for eight hours at slower speeds and then swap the inserts at the changeover shift, rather than replace the tips three times per shift by running faster. We get a higher volume of parts by running like that, and the Rocol coolant helps us hugely in extending the life of our tips.”

The improvement to tool life and machining performance can largely be accredited to the extremely high-pressure additives that provide medium- to heavy-duty machining capabilities with good surface finish on a range of ferrous and non-ferrous materials. Furthermore, the semi-synthetic fluid enables the customer to rationalise one fluid for both machining and grinding operations.

Commenting upon the changeover from the previous fluid supplier to Rocol, Reid says: “There were no issues whatsoever. However, with so many machines on site, it was quite a lot of work, which meant we had to implement the change over an extended period of time. One of the things I would recommend is that you clear everything out of the machine and clean through the system. This was hard work for the guys, but it’s critical that you completely clear out the machine.”

As a manufacturer that has opted for the Rocol Ultracare package of support, the team at Abbey Tool and Gauge has nothing but praise for the service.

“Alastair and I receive a report around four hours after the Rocol engineer has visited,” says Reid. “This report outlines a detailed state of every machine and gives us peace of mind.”

Providing insight from a Rocol perspective, Ian Fenney from Rocol says: “The process has run really smoothly and we’ve changed the fluid in all of the machines. We cleaned the machines out and started afresh. Whether we follow this complete clean-out process or not depends upon the fluid we are providing, but in this instance, there were key differences between the existing coolant and the product that we proposed.”

Alluding to the properties of Ultracut 370EP, Fenney continues: “All fluids will cut to a certain degree, but finding the right one for the customer, especially in a subcontract shop like this – there will always be a multitude of materials and machines. With Ultracut 370EP, we have something that ticks every box. At Abbey Tool and Gauge, they are both cutting and grinding with the same fluid on everything from cast iron through to Inconel.”

Concluding upon the Ultracare service package, Fenney says: “On this particular account, we supported the fluid changeover and cleaned out a selection of machines before the Abbey Tool and Gauge team took over and finished the project. Thereafter, we come in every fortnight to ensure all the machines are HSE compliant.”

For further information
www.rocol.com

Styles Precision brings wire EDM in-house

To eliminate the cost and lead times associated with outsourcing its wire eroding requirements, Worcestershire-based Styles Precision has invested in a new Sodick ALC600G from Sodi-Tech EDM. This bold investment is also helping to attract more work from both existing and new customers as the company looks to continue its growth over the next five years.

“We tend to buy high-end machine tools, an ethos that we’ve transferred to our first wire EDM, a Sodick ALC600G, which we bought with the help of a successful grant application via the RDPE Growth Programme,” explains the company’s managing director Tony Styles. “Investing in top-end machines helps us to attract high-value work, often in energy and power-related sectors such as steam turbine, renewables and oil and gas.”

Styles Precision previously subcontracted its wire EDM requirements, maybe not enough to consider buying a machine, but the company knew there would be additional opportunities if it could offer wire EDM in-house. Therefore, the company concluded that investing in the Sodick ALC600G would be a logical and exciting step forward.

“We’ve already been busy wiring many different parts, including special profile gauges,” says Styles. “Recently, we won a tender to manufacture a family of intricate, high-value steam turbine wear parts, which have a particular profile in the bore. We use profile gauges as an initial check of the labyrinth’s profile form during machining operations. In addition, the labyrinths are themselves split into numerous segments: we have around 240 specific segments to wire from machined rings measuring between 300 and 600 mm in diameter.

“We have some fascinating projects on the go at present, so the ALC600G will make a big contribution to the ongoing success of our business, particularly as we will soon be running it lights-out,” he concludes.

For further information
www.sodi-techedm.co.uk

Houghton International secures award double

Houghton International, an innovator in the field of electromechanical asset repair, maintenance and life extension, competed against companies from across the UK to secure two accolades at the Make UK National Awards. The company won SME Manufacturer of the Year and came runner-up in the Developing Future Talent category. Michael Mitten, CEO of Houghton International, says: “Taking home not one, but two national accolades is testament to our positive, innovation-led culture, excellent people, and the way we go about our business with integrity at the heart of all we do.”

For further information www.houghton-international.com