Zeiss to co-operate with Borg Automotive

Zeiss is entering into a co-operative project with Borg Automotive, an independent remanufacturer of automotive parts. Researchers at the Zeiss Innovation Hub @ KIT will be working closely with Borg Automotive developers and production engineers on the project over the next 12 months. The project will focus on researching and implementing new visual and automated solutions for modern remanufacturing processes that enable an even better component quality, performance and service life.

By remanufacturing used components it is possible to reduce waste and, at the same time, cut the resources and emissions required to manufacture new components.

“After remanufacturing, used parts have the same functionality, safety and reliability as new parts,” says Max Riedel, head of the Zeiss Innovation Hub @ KIT. “We would like to develop processes with Borg Automotive that will allow us to base even more reliable future predictions about the life of remanufactured parts on measurements and models.”

Grzegorz Pawłowski, group technology director at Borg Automotive, adds: “Testing components in the remanufacturing process is one of the most important steps in determining which parts are suitable for reuse: it defines the lifespan and quality of the product. Our ambition is to use automated systems in the processes increase process efficiency and further improve quality standards.”

Circular economy is one of the Zeiss sustainability focus topics. Borg Automotive also bases its business model on the circular economy, in which it is possible to extend the lifecycle of vehicle parts. Borg Automotive has recently had comparative lifecycle assessments performed on its eight product groups. These assessments show a tendency for 60% less CO2eq, 42% less energy (MJ) and 70% lower consumption of natural resources (Sb-eq) compared with newly manufactured products.

For further information www.zeiss.com

Huge time savings achieved with Sylvac solution

Excel Precision, a prominent player in the UK’s EDM sector, recently worked with Bowers Group to address a complex machining challenge faced by a machine tool company. The solution cut the client’s component setting time from around a week to less than an hour, also resulting in a 12-week reduction in production time.

Steve Batt, technical director at Excel Precision, says: “Our innovative solution transformed a complex and time-consuming process into a highly efficient one. By incorporating innovative technology from Bowers Group and smart engineering from our team here at Excel, we not only met the client’s precision requirements but also significantly increased their annual production capacity by reducing production time.”

The client had a precision issue with a deep-seated bore. The initial approach involved using a conventional DTI but proved inefficient, taking 5-8 days to achieve the required runout. This lengthy timespan was primarily because of the inability to observe the part’s movement during adjustments in the confined bore, which extended to a depth of 350 mm.

Available from Bowers Group, the Sylvac D62S digital display and PS12D digital probe were the solutions identified. The D62S sits on a carbon-fibre tube with a wire passing through, connecting it to the two digital probes. A specially developed mechanism allows one probe to take measurements in the X direction and the other in the Y direction, ensuring precision despite the tight confines of the bore.

Immediate feedback shows a dramatic reduction in set-up time, enabling the client to set the component within an hour, a significant improvement from the initial 5-8 days. Additionally, when combined with a custom fixture, it improved the client’s production capacity by reducing production time by at least 12 weeks.

For further information www.bowersgroup.co.uk

World-first in composites stress testing

StressMap, a specialist in residual stress metrology using the contour method, has invested in two new capabilities to help customers prolong the life and control distortions of critical mechanical components in the aerospace, motorsport and defence industries.

In its quest to making cutting-edge residual stress engineering technology available to industry, StressMap has designed, built and commissioned a new wire cutting machine that facilitates contour method measurements in polymers, ceramics and composites. Before this machine, it was only possible to measure electrically conductive materials (mainly metals), since the only cutting technique available was wire EDM.

StressMap’s invention is the fruit of a year’s worth of research and is the only machine in the world that can cut these non-conductive materials with the required quality. Specialist researchers presented and scrutinised the first results obtained in a PEEK pipe at a conference in the spring, with further structures currently undergoing tests.

Another new capability for StressMap is a laser peening machine, which will see collaborative use with a Formula 1 team as it looks to test engine components. This technique induces beneficial residual stress at the surface of key components, preventing cracking and prolonging their life.

Over the past decade, StressMap has delivered over 150 projects for 80 customers across the world. Applications of the company’s residual stress measurement expertise vary widely, and include: additive manufactured titanium components; nickel superalloys for turbine discs; and cobalt-chrome alloys for bio-medical use.

StressMap has also developed strain scanning simulation software in conjunction with STFC in Harwell Oxfordshire to improve the quality of neutron diffraction measurements by maximising accuracy in strain measurements and providing a high level of positional accuracy and repeatability.

For further information www.stressmap.co.uk

Rainford offers complete tool investigations

A UK specialist in micro-machining solutions, Rainford Precision, has invested in a Keyence digital microscope to provide a complete tool investigation and consultancy service for customers in the UK and Ireland.

The company’s managing director Miles Evans says: “When you are servicing customers with tools below 0.2 mm in diameter, diagnosing and optimising tool life and performance is a challenge. The Keyence system will enable us to provide a unique service to our customers within the cutting tool marketplace.”

With a magnification range from 100 to 1000, Rainford’s experts can analyse standard and micro-tools then investigate and resolve the barriers to optimum performance.

Cutting tools smaller than 0.5 mm in diameter can naturally pose issues when investigating performance and tool life issues. With the Keyence VHX-970FN, Rainford can provide an aftersales service aimed at delivering improved tool life, machining performance, productivity and consistency.

By investigating the wear characteristics of customer tools and armed with the cutting data, the company can diagnose issues from a multitude of factors. For example, if the cutting speeds, feeds and machining parameters are impacting performance, Rainford will be able to diagnose this from investigations with the Keyence microscope. Likewise, concentricity, tool holding and the associated concerns of rigidity, balance and stability could also be diagnosed and potentially rectified through Rainford’s service and product portfolio.

For existing customers, the service will provide a comprehensive feedback loop with full reporting and recommendations to maximise the machining performance of tools purchased through Rainford. Additionally, all potential customers who may be experiencing issues with their current cutting tools, whoever the manufacturer, and want investigate potential solutions, will be able to send their tools to Rainford’s experts.

For further information www.rainfordprecision.com

Blue Diamond back in UK hands

Blue Diamond Technologies is returning to UK ownership following its purchase, four years ago, by Swedish polymer engineering company Trelleborg Group. Incorporated in 1977 as a stockist and distributor of engineering and industrial components, members of the Worley family were the original owners of Blue Diamond. It is two of the original directors who are responsible for its re-acquisition now. Richard Worley, former managing director, and his brother, James, former operations director, aim to build on the company’s previous reputation for reliability and service, setting it back on a path for growth.

For further information www.blue-diamond.co.uk