REVVING UP PRODUCITIVTY FOR MOTORSPORT MANUFACTURER

Founded in 2016, subcontract machine shop HSM Components in Deeside has recently invested in CADCAM software from Open Mind Technologies. Specialising in the manufacture of bespoke components for customers across a multitude of sectors, the company recently reached the capability limits of its previous software – and that is where the hyperMILL CAM system has stepped in.

“I had pretty much reached the limits of my old software, so I needed to get something more advanced,” says Steve Rigby, managing director at HSM Components. “hyperMILL was the perfect choice for my business.”

The previous CAM system was creating a level of frustration at HSM, especially on more challenging components.

“In comparison to our previous system, it’s like comparing a Ferrari to a pushbike,” says Rigby. “The old software was more geometry-based, so if you had a complex part it really did become an exercise in CAD skills. Now, with hyperMILL, it works off surfaces and surface edges, so it’s all model-based. There’s also a lot more functionality to the system. Initially, I found hyperMILL a learning curve as it is more advanced, but the more time I invested in the system, the more I got to grips with it. The possibilities for our business are incredible.”

The Flintshire-based manufacturer recently won an order to manufacture big-bore billet engine blocks on Suzuki Hayabusa motorcycle engines for a motorsport customer – a project the company would not have been able to undertake without hyperMILL. The challenging project also required specialist tooling to machine the engine blocks from aluminium 6082 billets.

“I wouldn’t have been able to take this part on with the old software,” states Rigby. “hyperMILL has helped immensely and made this project possible. One of the biggest positives is the hyperCAD-S system from Open Mind. When you come to doing offline programming, not everything is straightforward. Very often you have to do quite a bit of CAD work, such as creating surfaces and containment boundaries. With the hyperCAD-S system within hyperMILL it’s very easy to use and has excellent surfacing tools.”

Recalling the implementation of hyperMILL and integrating it into the business, Rigby says: “As I don’t have five-axis capabilities, Open Mind can give you the exact modules that you need. This makes it more cost-effective for me as a small business owner. Despite the high-quality reputation of the brand, the purchase price was on par with other systems. Furthermore, the Open Mind team were extremely helpful and said that they could strip out any particular modules that we may not need. Having to learn a new CAM system is a challenge, especially with a suite like hyperMILL that has so much to it. Our initial strategy was to re-program existing legacy parts that we were already running with our old software.

“I noticed a huge reduction in cycle times straightaway and surface finishes are much better with hyperMILL,” continues Rigby. “Additionally, the cycles are more efficient and we are cutting less ‘thin air’ than we were with the previous system. hyperMILL is just better all round, which is something we would expect from a more advanced system. It really has hit the mark and given us what we needed.”

HSM Components encountered several challenges with the motorcycle engine block, such as machining water jacket slots around the cylinder bores as well as the machining of a pocket at the end of the cylinder head for the cam chain. The water jacket slot is 6 mm wide and 50 mm deep. Notably, the pocket for the cam chain goes all the way through the engine block and has tapered walls. Both required specialist tooling and creative machining strategies that according to HSM were a breeze with hyperMILL.

Commenting upon the project, Rigby says: “This customer is a specialist race engine builder for whom we already manufacture several products. They brought a new project to us to manufacture small batches of 5-off cylinder blocks to meet the requirements of its global customer base. Previously the company had been using overseas manufacturers with a minimum batch quantity of 10 off and a longer lead time. By working with HSM Components, this customer can reduce their order volume, inventory and lead times.

“With regard to the aluminium engine blocks, each block requires 10 hours of machining with four individual set ups,” he adds. “To support this project, we had to manufacture special fixtures, acquire bespoke tooling from Quickgrind and adopt a leading CAM system from Open Mind, but the benefits for the customer have been significant.”

Machined on a three-axis Hurco VMX42, programmed with hyperMILL and subsequently adding specialist cutting tools – this combination has helped HSM Components to minimise the cycle time for these challenging engine blocks.

Concluding on the project, Rigby says: “We initially completed three engine blocks as a trial for this new customer and, by improving the quality and lead time of these parts, we are now working on another batch of five engine blocks. The tool paths with hyperMILL are also improving our surface finishes. The opportunity for HSM Components is to now manufacture additional components for this customer, which sells spare parts and builds bespoke motorsport engines for everything from grass track racing and hill-climbing to performance vehicles that are exported worldwide. By utilising our high-end hyperMILL CAM system in conjunction with the specialist cutting tools from Quickgrind, we have little doubt that we can facilitate all the needs of this client.”
For further information www.openmind-tech.com

MTC to train Britishvolt apprentices

Apprentices at low-carbon battery manufacturing pioneer Britishvolt are to carry out their training at the Coventry-based Advanced Manufacturing Training Centre run by MTC Training. They will spend their first of four years at the AMTC before dividing their time between the centre and Britishvolt facilities. The first cohort of apprentices will begin in September, with the potential for hundreds more to follow in coming years. Britishvolt expects to employ more than 3000 people at its Northumberland gigafactory and recently announced a £200m battery manufacturing scale-up facility at Hams Hall in Warwickshire.
For further information https://the-amtc.co.uk

35,000 visitors attend BIEMH 2022

It was a long-awaited return for the BIEMH exhibition last month and it returned with figures that speak for themselves: an estimated 35,000 visitors from a total of 52 countries; more than 1400 exhibiting companies from 28 countries; more than 3400 machines, products, services and innovations; and 300 major buyers invited. The BIEMH biennial machine tool exhibition held its 31st edition in Bilbao at a key moment to observe developments in the sector. In addition to the show, 230 national and international speakers delivered 68 hours of conferences.
For further information https://biemh.bilbaoexhibitioncentre.com/en

Deal signed for FITMA-Latin America

Gardner Business Media and the Association for Manufacturing Technology (AMT) have signed a co-operation agreement to organise, produce and promote FITMA, Latin America’s premier manufacturing trade show connecting contract manufacturers, OEMs and equipment technology suppliers from around the world. After its successful launch in 2022, the first biennial FITMA event to operate in partnership between Gardner Business Media and AMT will debut in June 2023 in Mexico City.

Rick Kline Jr, president of Gardner Business Media, says: “After a successful launch of FITMA in 2022, the addition of AMT’s work with us going forward is going to accelerate the growth of this event and help us build a major metalworking opportunity in Mexico and for all of Latin America.”
For further information www.fitma-la.com/en

PECO fast-tracks another Sodick machine

A manufacturer of products for model railway enthusiasts has placed an order for another Sodick EDM machine. Devon-based PECO, which supplies its products to model shops across the UK and around the world, is about to enhance its toolroom with the addition of a Sodick ALC400G ‘i Groove edition’ wire-erosion machine from Sodi-Tech EDM. It will join three existing Sodick machines on site.

Established in 1946, PECO (Pritchard Patent Product Co Ltd) has its headquarters and manufacturing plant in the picturesque Devon fishing village of Beer, where the 150-employee business produces model rolling stock and track across eight different scales (from Z to G), as well as lineside/scenic and electrical accessories. Manufacturing in-house is clearly important to this progressive business, which is why the company runs a fully equipped tool room.

With its existing Sodick wire EDM passing a decade of service – and despite its ongoing excellent performance – PECO decided it would be prudent to look at a second wire-cut model.

“It was only ever going to be another Sodick,” states innovations manager Paul. Hitchcock. “Not just because of machine quality, accuracy and ease-of-use, but also the support and relationship we have with Sodi-Tech EDM. We saw a press article about the Sodick ALC400G with its ‘i Groove’ rotating wire mechanism and decided to undertake some trials.”

Applying rotation to the wire reduces wire consumption and allows the constant use of new wire surface for enhanced finishing and accuracy from the top to the bottom of the workpiece. This capability brings further peace-of-mind regarding precision and reliability, which is vital to a busy company such as PECO. The plant works a single shift but often leaves its Sodick machines to run overnight unattended.
For further information www.sodi-techedm.co.uk