Digital summit from Trumpf

Trumpf will stage a digital summit on 6 April focusing on nine topics, each of which will occupy a 30-minute presentation slot across the day (all in English). Highlights include: entry-level machines from laser cutting to bending; get into laser cutting cost-effectively; optimising production processes with integrated cutting and bending; introduction to a new shop-floor software solution for sheet metal processing; how to get started with automated panel bending; get into smart production with tailored solutions; and automated welding.

For further information
www.bit.ly/36detEz

Productivity springs forth at Baumann

A newly established manufacturing line for compression springs at a production facility of Baumann Springs takes place in a tumble-belt blast machine from Rösler. In short cycle times, the custom-engineered blasting solution produces surfaces that are optimally prepared for the subsequent coating operation. Furthermore, oil that carries into the shot-blast process is neutralised and, through the media cleaning system, separated from the blast media.

Located at the Stare Mesto, Czech Republic plant of Baumann Springs, the new production line accommodates different types of long compression springs made from EN 10270-2 spring steel. For cleaning and texturing (roughening) the surface of the springs prior to coating, the company uses a Rösler RMBC 4.2-HD tumble-belt blast machine.

“The Rösler solution impressed us not only because of its design, but its functionality,” explains Claudio Hertig, project manager global operations. “Another positive factor was the sturdy machine construction.”

Rösler’s RMBC 4.2-HD allows the blast cleaning of loosely tumbling compression springs with batch weights of up to 1,000 kg. Two Gamma 300G turbines, each equipped with a power of 11 kW, ensure high shot-blast intensity. These turbines, developed by Rösler, are equipped with curved throwing blades in a ‘Y’ design. Compared with conventional turbines, the specially calculated blade curvature generates very high media throwing speeds, resulting in up to 20% higher blast performance and, in turn, shorter cycle times.

Integrated blast media deflectors further intensify and accelerate the blast process. These special compressed air nozzles cause an additional blast-media movement. The automatic blast-media flow control allows not only the monitoring but also the precise adjustment of media flow to the respective workpieces. Media replenishment takes place automatically.

For further information
www.rosler.com

PRODUCTIVITY FLOWS AT RIVERSIDE FOLLOWING TURNING CENTRE INVESTMENT

As a subcontract machine shop, Riverside Precision Engineering provides round-the-clock one-hit machining for a range of sectors. When the company recently noted an upturn in business, it bought not one but two Nakamura turning centres from the Engineering Technology Group (ETG).
With a range of sliding-head turning centres machining components for the hydraulic, medical, brewing, valve, marine, rail, and oil and gas industries, the Blackburn-based company was utilising an ageing Nakamura WT250 turning centre for components beyond the diameter capacity limits of its sliding-head machines. To increase capacity and improve machine utilisation, the ISO9001-certified company reviewed the market and decided to purchase a Nakamura AS200L and a Nakamura AS200 turning centre. Both arrived in November, just three weeks after ordering the machines from ETG.

Founded over 31 years ago, the 13-employee business made its first venture into CNC machining in 2002, which was rapidly followed by volume machining on sliding-head turning centres. For components beyond the diameter realms of sliding-head lathes, the company has a variety of fixed-head single- and twin-spindle turning centres. From a precision and repeatability perspective, the Nakamura WT250 at Riverside Precision has been a stand-out performer over the years. However, the reliability and utilisation of a Nakamura WT250 that is over 20 years old in a machine shop that demands maximum uptime, is something that needed addressing.

Riverside director Scott Whalley recalls: “We have several older fixed-head machines from a variety of manufacturers, but the Nakamura WT250 has held tolerances and repeatability better than any other down the years. We reviewed the market and picked the Nakamura AS200 and AS200L from ETG for several reasons. Firstly, we had first-hand experience of the quality, longevity and performance of the brand. Second was availability. ETG had machines in stock and within three weeks, the two machines were on the shop floor and running. Equally important was the cost of the machines. We could’ve had cheaper machines on a comparative lead time and, similarly, we could’ve had larger machines at a lower cost. For us, it was investing in quality at a competitive cost for the long-term future of our business.”

The mix of machines was also an important factor for Riverside, which manufactures chain and conveyor components, as well as gas and water fittings.

“Components in the 50-65 mm diameter range that are beyond our sliding-head machines have been an issue,” says Whalley. “We run a lot of small-batch work, typically from 50 to 500-off, which is relatively simple to produce. For this we bought the Nakamura AS200 single-spindle chucking machine, while for more complex work in the 300 to 2000+ batch range, we bought the barfed twin-spindle Nakamura AS200L. This gives us the perfect blend of capability, flexibility and capacity. We have the AS200 chucker machine manually loaded with billets and the AS200L runs unmanned with a barfeed for longer batches.”

Like most subcontract manufacturers, Riverside Precision wants to maximise every inch of its floor space.

“We have 19 CNC machines at present and space is at a premium,” states Whalley. “The two new Nakamura models have slotted into the floor area of the old Nakamura WT250, giving us two machines in the space of one. Both of the new models are faster, more productive and can retain maximum uptime, unlike the old machine. We’re now looking at replacing some of our other large ageing machines with new Nakamura models from ETG. The beauty of the new acquisitions is that they provide very similar capacities inside the work envelope, but the machine footprint is far smaller.”

Despite the new Nakamura machines only being operational for a matter of weeks, the benefits are evident.

Says Whalley: “The cycle times on the new Nakamura models are much faster than our other large-capacity turning centres, there is less idle time and the kinematics ensure less ‘air cutting’. In fact, the single-spindle Nakamura AS200 chucking machine is quicker than our ageing twin-spindle models. The rapid rates are faster and the machines react a lot quicker. As a business, we’re extremely busy at present and the production of our larger components up to 65 mm diameter was a bottleneck. The new Nakamura machines have cut lead times from six weeks to just three on these larger parts.”

The stability and precision of the new Nakamura AS200 and AS200L have also been a revelation for Riverside, as Whalley outlines: “With our old Nakamura and some of our existing older machines, we have to take a trial cut before undertaking production, just to ensure the machine and tools are all set correctly and there’s no deviation between the parameters and the actual parts. This is not the case with the new Nakamura AS200 and AS200L. The new machines are much faster to set and the probes ensure all parameters are correct, so we have 100% confidence the components are correct every time without trial cutting or additional re-setting of parameters.

“The guys on the shop floor really like the new machines,” he continues. “As well as being faster and more productive, the control system has a graphic interface that is very intuitive and user friendly. Combining the new CNC interface with the simplified setting of tools in the work envelope, the team are much more confident using the new Nakamura machines.”

Still in their infancy at Riverside, it is difficult to draw direct quantifiable comparatives between the performance of the ageing turning centres and the new Nakamura machines. However, the company has instantly recognised that machine set-ups, cycle times and the throughput of orders are much improved. Similarly, the rigidity and kinematics of the new machines are apparent in improved surface finishes, tool life and the ability to ramp up machining parameters. While these savings will accrue over an extended period, one immediately evident point of note is the energy efficiency of the new machines.

“Despite being far more productive than our older and larger machines, the new Nakamura models draw significantly less power,” says Whalley. “We can immediately see that the machines are drawing less kVA than larger machines, and two Nakamuras are now drawing less power than one older machine. During colder periods, the heat generated by the older machines contributes to warming the factory floor. With the new Nakamura models, the area of the shop floor where they are situated is certainly colder. This temperature drop is noticeable and it’s due to the reduced power consumption, which can only be good for the environment and our operational costs.”

He concludes: “Overall, we’ve been delighted with the service, support and training that we received from ETG. As for the Nakamura machines, we knew we were investing in a quality brand, but now the machines are on the ground and running, the performance is making a huge difference to our business.”

For further information
www.engtechgroup.com

Official opening for AMRC North West

AMRC North West will help businesses unlock productivity and sustainability gains and keep the UK’s advanced manufacturing sector ‘ahead of the pack’, the Industry Minister said as he opened the new £20m applied research and development facility in Lancashire. Lee Rowley, Minister for Industry at the Department for Business, Energy and Industrial Strategy (BEIS), added that AMRC North West is a key innovation asset for the region and beyond.

The applied research centre, which sits at the heart of the Samlesbury Aerospace Enterprise Zone in Preston, has been built using a £20m grant from the Lancashire Enterprise Partnership Growth Deal and extends the University of Sheffield’s AMRC footprint across the north. It was opened by the Industry Minister accompanied by Koen Lamberts, president and vice-chancellor at the University of Sheffield, and Debbie Francis, chair of the Lancashire Enterprise Partnership.

For further information
www.amrc.co.uk

Major robotics conference

The Manufacturing Technology Centre (MTC) is to host a two-day conference that will drive the uptake of robotics and automation across UK manufacturing and address the widening productivity gap. ‘Robotics and Automation – A New Perspective’ will take place on 4-5 May and enable delegates from a range of industries to share insights into the transformational benefits of cutting-edge robotic technologies in development at the MTC.
Mike Wilson, MTC chief automation officer, says: “The UK lags behind many industrialised nations in its adoption of robotics – currently 24th in the world. Such a slow uptake is undoubtedly holding industry back. This conference aims to change that and instil confidence in manufacturers seeking transformation. Pioneers of robotics will be on hand to highlight successful projects that have reaped the benefits of intelligent automation, and help people make the right decisions.”

For further information www.bit.ly/3KHWVQ0