Flexibility for tool production and regrinding

Whether for tool production or regrinding – as a cost-effective ‘basic’ machine or as a fully automated model – the new Walter Helitronic Mini Plus tool grinder can satisfy any need for the effective and efficient production of tools from 1 to 16 mm diameter, machining even complex geometries in a single clamping. Re-grinding capacity is up to 125 mm diameter.

Available from Walter Ewag UK, the basic machine version is configurable with a wide range of efficiency options and various loading systems, extending to a fully-equipped ‘high-end’ tool grinder capable of all current and future applications in the small and medium tool diameter range.

The basis for the flexibility of the Helitronic Mini Plus is Walter’s proprietary gantry design, where the economical production of geometries in a single set-up is guaranteed by a HSK belt spindle with two spindle ends for up to six grinding wheels (as standard). In addition, the C.O.R.E. (Customer-Oriented REvolution) hardware and software architecture embraces the digital age by offering intuitive operation that facilitates machine set-up, operation, networking and maintenance.

Options available for the machine include an automatic grinding wheel changer for up to six wheel holders (maximum diameter 152.4 mm), including coolant supply, to ensure a safe wheel set change and maximum flexibility. In addition, for machines so equipped, a ‘torque increase’ option raises torque and removal rates by up to 60% for extra productivity.

For automated use, users can choose a top loader or robot loader, with three equipment packages.
For further information www.walter-machines.com

Haier Europe opens dishwasher factory

Haier Europe, part of Haier Smart Home, is expanding its manufacturing footprint with a new dishwasher factory at the company’s industrial site in Eskişehir, Turkey. With an investment of more than €40m, the facility will have capacity of 1 million units per year. The new plant features improved production capacity thanks to high automation levels with operating robots and 100% automatic measuring systems.

“Haier Europe keeps over-performing the market in terms of products and brands leadership, and is the fastest growing company in Europe,” says Yannick Fierling, CEO at Haier Europe. “The expansion of our industrial park in Turkey marks another step in the company’s growth strategy, and the investments are fully in line with our philosophy of zero distance to consumers.”
For further information www.haier-europe.com

iGas opens two plants in Abu Dhabi

iGas USA, one the world’s largest refrigerant gas suppliers, has announced the opening of two state-of-the-art production facilities in Abu Dhabi: a 2 million sq ft newly constructed refrigerant production facility located on 40 acres of land; and an 80,000 sq ft cylinder production facility with fully automated production lines set to manufacture DOT disposable refrigerant cylinders. The refrigerant production facility aims to manufacture 40,000 MTs of R32 annually, while the cylinder production capacity in the new DOT disposable refrigerant cylinder facility will reach 4 million cylinders per year.
For further information www.igasusa.com

Beko unveils new investment

Beko Egypt for home appliances, a subsidiary of Arçelik, has laid the foundation stone for its first factory in Egypt at the 10th of Ramadan Industrial Zone, with a land allocation of 114,000 sq m. The investment by Beko, which has its headquarters in Turkey, marks a significant milestone and will create more than 2000 jobs. In addition, the factory will develop local supplier ecosystems to deliver sustainable value for all industries while supporting the government’s long-term strategy to drive industrial localisation and establish Egypt as a significant production and export hub to overseas markets.

Scheduled to begin operations by Q4 2023, the ‘zero waste’ plant is projected to manufacture an annual capacity of 1.5 million household appliances, more than 60% planned for export to Europe, the Middle East and Africa as ‘Made in Egypt’, with around $250m in annual export potential. The first phase of the investment will focus on producing eco-friendly cookers and refrigerators.
For further information www.beko.com

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