ITC CUTS TOOLING COSTS AND CYCLE TIMES FOR TML

Celebrating its 30th year of business, Tml Precision Engineering is a tier oneand tier two subcontract manufacturer that invests in the latest technology to service leading OEMs and supply chains in the aerospace, motorsport, medical and renewable energy sectors. To extend its competitive advantage, the Norwich-based company utilises cutting tools from Tamworth-based Industrial Tooling Corporation (ITC).

Working to ISO9001 and AS9100, Tml has invested in multi-pallet five-axis machine tools from Matsuura and DMG Mori, turn-mill centres from Mazak, and turning centres from Mazak and Nakamura-Tome. With high-quality machine tools offering extended periods of unmanned machining, the company was looking to improve its tool life while simultaneously reducing cycle times and, consequentially, its commercial advantage. An initial market review led to ITC based on service capability and technical support.

Local ITC technical engineer Dan Smith called intoTml and initially trialled several ITC 2041 series of solid-carbide end mills for aluminium machining. Applied to a series of battery system components for a Norfolk-based automotive OEM, the initial trial proved fruitful with productivity rates and tool life both improving. The improved results led to the 2041 series and other aluminium specific end mills seeing adoption on the shop floor. This success also gave the manufacturer confidence to trial the Widia range of indexable turning tools. Results were once again impressive.

The Widia Victory series of CNMG and WNMG indexable inserts from ITC for machining steel and stainless steel were applied for rough-turning a family of more than 10 different flow regulator and pipe assembly components. Machined on one of the company’s Mazak Integrex turn-mill centres, the ITC engineer swapped out the previous inserts and retained ‘like-for-like’ cutting data with the four-edged inserts. The ITC Widia Victory turning series yielded a tool life of 16 parts per edge compared with the previous four parts per edge. This significant tool-life saving is proving hugely beneficial for Tml, especially as the pipe assembly parts are high-volume components manufactured throughout the year.

One of the parts in the assembly was particularly challenging, as Smith recalls: “Acomponent manufactured from stainless steel bar has a seam weld that results in intermittent cutting, which is why tool life was an issue. However, the performance of the Widia Victory turning series massively improved tool life, while another benefit was reduced insert changeovers and subsequent cost reductions. To further reduce costs in the turn-mill department, we introduced the latest Widia WCE4 series of solid-carbide end mills. Using 3, 4, 6 and 8mm diameter end mills with variable helix flutes, tool life improved and the variable helix enhanced surface finishes and reduced vibration during machining.”

Following the earlier successes established for aluminium milling and the subsequent introduction of small diameter end mills to the turn-mill machines, ITC had an opportunity to look at other milling projects.

An aluminium component machined regularly by Tml in batches up to 100-off required 30mm of metal removal on the face. Previously, the company was using a four-flute solid-carbide end mill from a rival supplier, which was resulting in poor tool life and surface finishes, primarily due to vibration and poor chip evacuation. Furthermore, with poor surface finishes and excessive noise and vibration, Tml had to use one end mill for rough machining and a second tool for finishing. The ITC engineer rapidly eradicated this requirement with the introduction of a 16mm diameter ITC 4104 series aluminium roughing tool with chipbreaker. To maximise the rigidity of the set-up, Smith introduced a Big Kaiser HMC chuck to complement the end mill.

The combination of the 4104 chip-breaker end mill and the Big Kaiser HMC chuck enabled Tml to take a full flute 30mm depth of cut and run at 10,000rpm with a 1.8mm step over and a feed rate of 7200mm/min. On a batch of 80 parts, the ITC 4104 series proved to be a more cost-effective tool that subsequently reduced the cycle time by upwards of 20% while improving the surface finish substantially – to the point that a secondary finishing tool was not required. The single tool machined the entire batch of 80 parts and saved more time with no additional tool changeover or cost implications.

In combination, the benefits of the respective tools have been significant after just six months of working with ITC. However, the most impressive result to date was the latest part subjected to ITC optimisation.

A large EN8 component for the entertainment industry requires 77% material removal, taking the part from 9kg down to just 2kg. On the rough facing of the component, Tml was previously applying a face mill, which was yielding a roughing cycle time of 1.5 hours. The ITC engineer swapped out the face mill for an ITC 16mm diameter 6054-16 series six-flute end mill with a chipbreaker. With a 50mm flute length, the 6054-16 series cut at a full 50mm flute depth with a 0.8mm step-over and a cutting speed of 4777rpm. Cutting with such aggressive material removal rates on a Matsuura MAM72, the stability of the end mill saw further enhancement with the deployment of a Big Kaiser HMC chuck that offers complete face and taper contact. The combination of the chuck and 6054-16 series end mill cut the roughing cycle from 1.5 hours to just 15 minutes. With a quantity of 60 parts, the cycle time reduction is equal to more than three days of machining.

Most engineers would be happy to deliver such a substantial saving for a customer, but not the engineers at ITC. On the same part, Smith identified an opportunity to remove a 90° indexable end mill for interpolating bores. Replacing the indexable tool with ITC’s solid-carbide 4081 series of four-flute end mills with AlTiN coating, another 45 minutes were shaved from the cycle time, taking the complete cycle time from 3 hours to just over 60 minutes.

Concluding on the working relationship with Tml, Smith says: “We’ve worked with Tml for a little over six months, but the results have been exceptional. This is a credit to the receptiveness of Tml to adopt new techniques that improve their cycle times and reduce tooling costs and consumption.”
For further information www.itc-ltd.co.uk

Mazak lauds recruitment open house

Yamazaki Mazak has declared its recent recruitment open house a major success.The event, which took place in April, attracted 22 attendees with 16 subsequently offered positions as trainee machine tool builders. It was open to all ages from education leavers through to career changers.

Christopher Bills, production manager -assembly at Mazak’s European manufacturing plant in Worcester, says: “We selected people mainly on attitude as these are trainee vacancies. With a good attitude we can train all the skills required to be a successful machine tool builder. I am delighted that all 16 who were offered a position accepted. The new recruits are now working in a variety of roles including electrical assembly, mechanical assembly and fitting roles.”
For further information www.mazakeu.co.uk

Subcontractor on a roll with Nakamura machines

As a subcontractor with a distinct niche in thread rolling, Dobson & Beaumont has been in business for more than 100 years. As well as machining nuts, the company cold-forms bolts and special fittings to work harden the thread, thus improving overall thread strength by more than 25% when compared to typical thread-cutting operations. Before rolling, the Blackburn-based company machines some of the most daunting materials known to the industry, which is why the company purchased a Nakamura-Tome AS200LMSY, followed by a Nakamura SC100X2, from the Engineering Technology Group (ETG).

Installed and running at the end of 2022, the SC100X2 is already reducing cycle times by upward of 30%. This is credit to several factors. Firstly, the new SC100X2 offers superimposed machining.

“Superimposed machining is a game-changer for our business, as we can now hit parts with two tools simultaneously by overlapping operations between main and sub-spindles,” explains Richard Guest, managing director of Dobson & Beaumont.“This has reduced cycle times noticeably already. On high-value motorsport studs, we have cut the cycle time from 3 minutes to 1minute 30 seconds.”

The sub-spindle can move not only toward the main spindle for component pick-up, but also in synchronicity with the lower turret for machining operations that can take place while the upper turret is machining on the main spindle.

“We machine hard materials such as MP35N and AERMET 100, which has a tensile strength of 1900 Pa,” says Guest.“Before the arrival of the SC100X2, we had to sub many of these parts out, which added 2-3 weeks to our lead time. Now, we can machine in-house and keep lead times to just days while eliminating additional subcontract costs.”
For further information www.engtechgroup.com

Discover the complete manufacturing ecosystem

Subcon returns to the Birmingham NEC next week (7-8 June), bringing together the full manufacturing ecosystem for the UK’s longest-established subcontract manufacturing supply chain show. Over 200 UK and international suppliers will be present at the 46th edition of the exhibition, covering assembly work, CNC machining, metal fabrication, electronics, component parts and more. The exhibition organiser anticipates more than 4000 visitors, all of whom will benefit from free access.

Alongside the exhibition, two conference theatres will provide topical content on the challenges, pain points and opportunities for the manufacturing industry, including supply chain optimisation, AI and automation, agility and resilience, additive manufacturing, cybersecurity, sustainability, and digitalisation. These free conference sessions will showcase over 50 industry leaders revealing stories behind some of the UK’s most interesting engineering and manufacturing projects.
For further information www.subconshow.co.uk

Technoset upgrades with new Tornos Gamma 20

Technoset continually invests in its operations to ensure the company always has the latest equipment to improve operations, an ethos exemplified by its recent investment in a new Tornos Gamma 20. The company says that this Swiss-type lathe delivers precision and speed for complex machining and is ideal for high-volume production.

The main benefits of the Tornos machine are that it can perform many operations simultaneously, enabling high-volume throughput with no drop in the quality of finish. Notably, the liquid-cooled spindle can run up to 10,000rpm, delivering high levels ofprecision. According to Technoset, the Tornos is also built to last, delivering the same consistent results time after time – an essential trait for a companythat insists on a consistently high level of quality for its customers.

Technoset’s newTornos machine is capable of performing many different operations, supporting the fast production of complex components. Combined with Technoset’s other machines, the investment will allow the company to reduce lead times and offer an even better service.

While the machine is highly advanced and delivers elevated levels of performance, the Tornos Gamma 20 is also energy-efficient and low maintenance. These attributes bring down overall production costs for customers and enables Technoset to offer a wider range of services, at excellent value.

Technoset says it is always investing in its facilities with the addition of new technology. As a case in point, another recent arrival is a new Miyano ABX51/64 fixed-head turning centre.
For further information ww.techno-group.co.uk