British Steel to become world leader in special profiles

Forming part of a £26m investment by British Steel’s owner Jingye Group in the Skinningrove steelworks near Redcar, a travelling-column machining centre with a working envelope of 14,000 x 4100 x 1600 mm is currently being built in Germany by SHW Werkzeugmaschinen. It will arrive at Skinningrove towards the end of 2023, where it will be set up as a turnkey installation by Kingsbury, SHW’s sole UK agent.

Despite being of such large capacity, the Uniforce 4000 five-axis machine will nevertheless hold extremely tight tolerance on special rolled steel profiles produced in the mill. British Steel says that the combination of size and accuracy will set the company’s machining capability apart from that of other global players.

The rationale for the latest project is a legacy situation within British Steel that for the past 20 years has seen special profiles produced in Skinningrove transferred by truck 35 miles west to the group’s Darlington machine shop for processing. The resulting bottleneck limited throughput of the company’s special steel profiles and delayed its just-in-time delivery to world markets.

Dominic Hill, British Steel’s technical manager -special profiles, says: “We opted for this large milling solution from Kingsbury rather than those by other suppliers due to the high build quality of the German machine, as well as certain design features that are unique in this size range.One is counterbalancing of the head driven by twin ballscrews to compensate mechanically for droop, whereas the other OEMs offered less effective software compensation.

He adds: “The other significant plus point is the use of box guideways rather than linear guideways, which translates into higher rigidity, productivity and machining accuracy.”
For further information www.kingsburyuk.com

Wire EDM sparks productivity gains for Go Tools

Set up in 2012 to deliver precision tooling to companies in the north of England, Go Tools Ltd is a specialist manufacturer of precision die-cast dies and injection mould tools for a multitude of sectors. With an unwavering commitment to quality and service, the company has invested in high-end machine tools from the Engineering Technology Group (ETG).

One point of concern was an ageing EDM machine.Recalling this, Go Tools technical director Steve Barrowcliff says: “Our old EDM machine had inconsistent cut quality and poor precision levels that made us rely on the expertise of our staff to retain tolerance and surface-finish requirements. As an old machine, it was also unreliable and a potential concern due to the amount of EDM work going through the shop floor. We investigated the market and the Mitsubishi MV1200R wire EDM was the perfect fit for our business. The programming platform of the Mitsubishi EDM was 10 times better, as was the accuracy and the speed of cutting. Simultaneously, we needed a spark erosion EDM, so we also invested in the OPS Ingersoll Gantry Eagle 400 – both machines were the result of the technical expertise and support of ETG.”

This first delve into Mitsubishi EDM technology proved a resounding success with productivity, reliability and quality improving significantly. So, when the company found its Mitsubishi MV1200R EDM at capacity some years later, the company naturally went out and bought another machine that was the same as the first.

“Our first Mitsubishi MV1200R improved our cycle times by more than 50% and the precision levels and surface finishes were impeccable, so when it came to buying a second machine, we didn’t need to look anywhere else,” concludes Barrowcliff.
For further information www.engtechgroup.com

Free automation and robotics conference

The Manufacturing Technology Centre (MTC) is to host a two-day conference at its Coventry facility to drive the uptake of robotics and automation across UK manufacturing. ‘Robotics and Automation – A New Perspective’, will take place on 10-11 May, exploring the future of automation and demonstrating the opportunities available to UK industry.Delegates will get the chance to share insights into the transformational benefits of robotic technologies and learn how automation can improve productivity and drive global competitiveness.

The free event will bring together high level speakers from industry, government and academia. Mike Wilson, chief automation officer at the MTC, says: “It’s an opportunity to meet, discuss and address the challenges with the adoption of automation and robotics. Delegates can listen to inspiring talks by industry experts, join educational workshops, discover innovative technologies or simply network with like-minded individuals.”
For further information www.bit.ly/3E4t6Z0

Horn mourns passing of managing director

Lothar Horn passed away earlier this month at the age of 66 after a long illness. As managing director of Paul Horn GmbH in Tübingen, Germany, he shaped the company into an international manufacturer of cutting tools, with production sites in the UK, Italy, the Czech Republic and the US, alongside subsidiaries in France, Hungary, China, Mexico, Turkey and Thailand. He joined the company in 1991 as son of the founder, Paul Horn, becoming managing director in 1995. In 2018, Lothar passed the reins to his son Markus.The Horn Group says it has lost an outstanding entrepreneur and a wonderful person.
For further information www.phorn.co.uk

AFRL upgrades rocket fabrication capabilities

The Rocket Propulsion Division, part of AFRL’s Aerospace Systems Directorate, recently modernised its fabrication shop in California with five new CNC machine, including a wire EDM machine, a die-sink EDM machine, a small-hole EDM, CNC milling machines and three CNC lathes.

“The recently upgraded machines provide AFRL with an increased capability to fabricate components of higher complexity and provide customers the benefit of being able to keep more of their work on-site, reducing program costs and turnaround time,” says Ben Gleason, lead fabrication technician. “The machines are equipped with similar CNC control units to lessen operator training. More accurate spindles and electronic part probing reduce set-up time and increase precision.”

Specifically, the new equipment will increase accuracy on multi-sided and complex parts, while improving operator safety and allowing for a cleaner, safer working environment.

“The unique skills of these devices allow them to machine tight tolerances with exotic materials such as superalloys, additively manufactured metals, polymers and composites,” says Lt Col Ammy Cardona, AFRL branch chief and materiel leader for the Experimental Demonstration Branch.

AFRL’s Rocket Propulsion Division designs and manufactures components for liquid rocket engines and solid rocket motors. The newly upgraded fabrication shop allows the laboratory to manufacture unique, one-of-a-kind rocket components that scientists and engineers can test in experiments, such as proof of concepts for new technologies.

The automation of the new machines will also ensure product quality and timeliness, which helps the team make accurate decisions of scheduling and production to meet the demand of AFRL’s test schedule.

“The new machines support highly precise cuts which eliminates waste and saves money on material and human error in the fabrication process,” says Gleason.
For further information www.afrl.af.mil