GETTING THINGS OFF THE GROUND

MACH Machine Tools, a supplier of CNC and manual machines and machine shop equipment to UK and Irish component manufacturers, has recently supplied, Hill Helicopters, a vertically-integrated manufacturer of luxury private helicopters, with two new manual machines. The machines, comprising a best-selling MACH VS-1SP (Super Precision) vertical turret-type mill and a MACH L-1340 lathe, were installed at Hill’s modern 5250 sq ft Development Centre in Rugeley, Staffordshire in May and October 2022, respectively.

The investment in both MACH models was made to increase the machining capacity and capabilities of the company’s newly established tool room and, by doing so, help ‘free-up’ its production-led CNC machine tools from having to be available to undertake routine and less complex and critical machining operations.

Although only recently acquired, the two MACH machines have already proved their worth and are an important part of the company’s overall in-house machining resource.

The two MACH machines, along with other manual equipment, are now in-situ within a specially-designated and demarcated tool room positioned within the company’s impressive machine shop facility.

Notably, the tool room plays a crucial ‘supporting’ role in helping the company to achieve its daily production targets which, at present, are focused on designing, developing and machining high-precision prototypes and pre-production parts (and their attendant machining processes) for its HX 50 (private) and HC 50 (commercial) helicopter platforms.

To date, the two MACH machines have earned their spurs machining one-offs and small batch series, as well as machining intricate features, such as shaft thread forms, on specific parts. The machines also manufacture a range of jigs and fixtures which, when completed, are transferred to the production-oriented CNC machines in the machine shop.

Explains Mark Webb, Hill Helicopter’s lead production engineer: “The MACH machines are accurate, fast, flexible and reliable, and are helping us improve our productivity and process efficiencies. Our tool-room facility acts like a ‘business within a business’. It exists to serve and support our wider machine shop needs and takes pressure off our production-oriented CNC machines which, to meet our tight deadlines, are always in high demand.”

The acquisition of the two MACH machines followed a chance meeting earlier in the year between Webb and representatives of MACH Machine Tools at the MACH 2022 exhibition in Birmingham.

“We attended the MACH show at the NEC primarily to look at acquiring a range of ancillary equipment production like wash tanks, welding kit, rumblers and polishers for our machine shop,” says Webb. “During our attendance we came across MACH Machine Tool’s stand and there, in plain view, were a number of manual machines that, I believed, could do an important job for us.”

He adds: “I met Dave Andrew from MACH Machine Tools to discuss our requirements and, after agreeing the scope and scale of the investment and finalising all the details, ordered a manual mill and a manual lathe there and then.”

The MACH VS-1 SP manual mill is built to exacting quality standards that include: hand-scraped hardened and ground dovetail slideways; Turcite B on the ways, slideways and gibs; and hardened and ground table tops and T-slots with nickel-coated lead screws. The machine is equipped with a 3 hp EVS Yaskawa-controlled inverter motor that provides absolute control over the infinitely variable spindle speeds (up to 5000 rpm). Standard features include a two-axis Newall DRO, low-voltage LED lighting, power feed to the X axis, coolant equipment and a stand-on style composite base splash tray. Offering travel of 850 x 305 x 127 mm in the X, Y and Z axis respectively, the MACH VS-1 SP comes with a 1245 x 229 mm worktable that can accommodate workpieces weighing up to 340 kg.

The MACH L-1340 lathe feature a heavy-duty spindle (2.2 kW/2570 rpm) housed in a robust headstock for increased flexibility and improved productivity. Notably, the machine’s headstocks feature British Matrix manufactured clutches, nylon safety pins in the end train and chromium molybdenum gears and shafts. The machine offers 1000mm distance between centres, 171mm height of centres, 180 mm X axis, 1000 mm Z axis and a Newall DP 500 two-axis DRO. Also supplied are three- and four-jaw chucks and quick-change tool posts. The lathe features induction-hardened and ground gears and shafts for long service life. Of particular note, Meehanite cast, anti-vibration and stress-relieved beds offer high accuracy and process reliability featuring Turcite B coating between the bed and carriage, while anti-float backlash eliminators deliver improved accuracy, surface finish and tool life.

With a VS-1 SP already in stock and available for immediate delivery, MACH Machine Tools decided to loan Hill Helicopters an ex-demo L-1340 lathe from its showroom until a new lathe become available.

“We appreciated MACH’s flexible and proactive approach that would enable the mill and lathe to be delivered to us at the same time,” recalls Webb.

Although MACH Machine Tools’ involvement with Hill Helicopters is currently limited to the supply of one manual mill and one manual lathe, this could change, quite dramatically, in the future. The planned move in 2024 to a new 330,000 sq ft manufacturing facility in Stoke, will enable the company to ramp up production to meet its Year 1 and Year 2 targets. This will translate to building and delivering 250 and 500 helicopters, respectively, to customers around the world, presenting opportunities for the relationship between both companies to grow.

Continues Webb: “We will be increasing our headcount quite considerably in the years to come [from 40 to over 400] and, to help address future skills shortage issues and problems recruiting talented staff, we will create an apprentice training school at the new facility. To ensure new recruits learn basic and foundation level engineering and machining skills and competencies, it’s our intention to invest in a number of additional manual machines to train apprentices ‘the Hill way’.”

This is another example of the company controlling the means of production, of its commitment to vertical integration, and of developing and bringing in-house, as many manufacturing technologies and processes as possible.
For further information www.machmt.co.uk

Hybrid mill/grind machine cuts cycle times

Manufacturers can now achieve faster processing times thanks to the hybrid milling and grinding capabilities available on the new Mikron MILL S/X (U) series from GF Machining Solutions. The new series combines milling and jig grinding in a compact footprint.

According to GFMS, these three- and five-axis machines deliver accuracy, precision, speed and best-in-class ergonomics. The various models can operate as stand-alone machines or, to improve productivity, can be integrated with automation systems to create flexible manufacturing cells.

Featuring Automated Machine Calibration (AMC) from GFMS and an advanced cooling system that cools the machine’s structure and spindle, changes in ambient temperatures or heat generated within the work environment during machining operations do not affect the machine’s ability to deliver high accuracy, even during long machining runs or extended periods of operation.

The AMC package allows operators to recalibrate the machine and recover its original precision, at the press of a button.

In MILL S and X machines, GFMS accommodates the grinding set-up within the standard footprint, while the laser measuring system and dressing spindle (boasting an increased spindle speed from 3000 to 20,000 rpm) are located close to the working area to ensure quick and fast grinding. In addition, the dressing spindle sits at a slight inclination in order to dress any type of grinding tool.

GFMS can equip the machine with an additional AE sensor to track grinding operations. Additional AE sensors are located on the machine table, allowing operators to adapt the process using the automatic tool detection cycle. This cycle, developed by GF Machining Solutions, avoids air grinding by detecting exactly when the grinding tool touches the part – thereby optimising the process.
For further information www.gfms.com

Tyrolit picks up the pace with Cerabond X

Stock removal taking longer than expected and product wearing out too quickly? Tyrolit says that its Cerabond X brings a new dynamic to the process by maximising stock removal through enhanced abrasiveness, reducing working times and prolonging product lifetime in combination with a uniform finish.

Widely used in the market, ceramic grain is one of the most common forms of abrasives, known for being sharp, tough and strong. However, despite the advantages that ceramic abrasive grains have regarding stock removal, the best grain in the world can only be utilised for a limited time should it not be combined with a quality vulcanised backing and bond structure.

Tyrolit’s new self-sharpening ceramic grain, combined with a bespoke bonding system, is said to enable optimal bonding of the ceramic grain. New to the market, the Cerabond X product range not only includes fibre discs, but also a full range of metal removal products, including cut-off wheels, rough grinding wheels, flap discs and belts, which are suitable for all steel and stainless steel stock removal.

The structure of the ceramic grain in the new Cerabond X products not only provides extremely fast stock removal, but also shorter cutting time, reports Tyrolit. With the added benefit of flap discs featuring a trimmable core, the products deliver 30% higher stock removal rates. Furthermore, the entire disc can be utilised, maximising lifetime through the need of fewer discs.

Due to the durability of ceramic grain, combined with the bonding structure, Tyrolit says that the products perform better than others when used at high pressure, making the new Cerabond X system suitable for heavy-duty applications.
For further information www.tyrolit.co.uk

Cost-efficient finishing of balancing weights

Today, centrifuges are the most commonly used systems for cleaning and recycling the process water required in mass finishing operations. A case in point is Wegmann Automotive, a specialist supplier of balancing weights, which is today utilising a fully automatic Rösler Z1000 centrifuge.

As a pilot customer, Wegmann expanded the software for its centrifuge with the ‘advanced version’ of the digital process water management system from Rösler Smart Solutions.

Wegmann makes its balancing weights as stampings from steel and galvanised steel, as well as die-castings from zinc or zinc alloys. Eugen Weizel, department manager for mass finishing and coating, says: “After the stamping or die-casting process, the weights undergo a part-on-part mass finishing operation in a rotary vibrator. The goal is to remove the residual oil left over from the stamping process and the water-based mould release agent that remains from the die-casting operation. At the same time, the compound provides corrosion protection for the steel parts, while the zinc die-castings require a certain surface tension for the subsequent coating step. The surface tension is carefully monitored and controlled.”

Since the process water is recycled, the process water cleaning operation – with a fully automatic Z1000 centrifuge from Rösler – and control of the compound concentration are key factors that determine the quality of the balancing weights.

Says Wegmann’s Manuel Salomon: “When the mass finishing machine and the centrifuge were commissioned, we quickly recognised that there is a close correlation between the process water quality and the quality of our products. Therefore, we carefully measured the compound concentration once per week and recorded the measured results. This allowed us to define the compound concentration for our finishing process and correct it as needed.”
For further information www.rosler.com

CO2 footprint calculator adds up for PPS

A new carbon footprint calculator for metal polishing is the result of an exciting tie-up between industry and academia. Professional Polishing Services (PPS), which has created three new jobs in the past 12 months, has tapped into funding and advice from the University of Birmingham’s ATETA programme to develop a digital process that will help it identify thousands of pounds of savings on energy costs.

The project involved mapping out manufacturing flows and installing high-end data logging sensors in key places to monitor the real-time power consumption of industrial equipment.
Notably, the equation takes account of several variables, including type of material and speed of job, to provide robust calculations that work out carbon footprint and identify potential savings.

The West Bromwich-based company is not looking to keep this IP to itself. Instead, PPS is planning to roll-out the calculator to the rest of the finishing sector in a bid to help industry move towards net zero.

Kirsty Davies-Chinnock, managing director of PPS, says: “Our bespoke stainless steel and non-ferrous polishing services are energy-intensive, so it made perfect sense to look at how we could monitor costs, especially with prices going through the roof. We now have a carbon calculator that can instantly work out the footprint of each job we put on our lines, which is fantastic information to have. It gives our production team the opportunity to look at how we save energy, making us more competitive in the process. The next step will be to roll this out to the rest of our sector and we’re already talking to the university and our competitors to see exactly how we do this.”
For further information www.professionalpolishing.co.uk