Ensuring machine assembly accuracy

For machine-tool makers, achieving manufacturing efficiency depends on fast and accurate quality-control processes. With traditional error testing methods beginning to hinder operations, Takam Machinery recently turned to Renishaw’s XK10 alignment laser system to deliver precision, efficiency and speed.

In an increasingly competitive global market, the more traditional methods of identifying potential geometric and rotational errors, including granite squares, dial gauges and autocollimators, were impeding Takam’s manufacturing and quality-control processes.

To resolve the inefficiencies and inconsistencies from a range of traditional error-measurement tools, Takam is benefiting from Renishaw’s XK10 alignment laser system. An all-in-one digital measurement solution suitable for a range of different CNC machine tools, the XK10 comprises: a launch unit for primary laser transmission; wireless transmitter and receiver units; a portable display unit; and a fixturing kit. An additional kit allows users to carry out parallelism measurements.

The XK10’s compact size, wireless connectivity and versatile fixturing means it is suitable for use in many different configurations, enabling error measurement across all types and sizes of machine tool. It can check that linear rails are straight, square, flat, parallel and level, and check spindles and chucks to assess the direction and coaxial correctness of rotary machines.
Huang Zhifeng, factory manager at Takam, says: “The system has increased overall testing efficiency by at least a factor of three compared with previous traditional testing tools. For example, we needed two operators working for more than four hours just to measure the linearity, flatness, verticality and parallelism of a 20 m gantry-type machining centre. But since we brought in the XK10, a single operator can complete the process in less than two hours, so the workforce can be allocated far more flexibly than before.”

For further information
www.renishaw.com

Muffett gearing-up for precision

Based in Tunbridge Wells, Muffett Gears makes regular investments in cutting-edge quality-control equipment. The company’s most recent addition is a case in point: a Crysta-Apex S9106 CNC CMM from Mitutoyo UK.

Director Mark Jagelman says: “The production of precision gears and associated components requires exceptional precision and the application of exacting quality standards through all stages of production and assembly. We recently decided to replace our existing CMM for a range of reasons. For instance, the machine needed an upgrade that was due to cost £50,000. In addition, we thought that our old CMM’s running costs, including training, services and calibration, were becoming exorbitant.

“After investigating various CMM brands and models, a successful demonstration of a Crysta-Apex S9106 CNC CMM at Mitutoyo UK’s showroom convinced us that this high-specification machine was ideal for our needs,” he adds. “In addition to providing the necessary levels of precision it also had the speed of operation that could keep pace with the high volumes of work passing through our busy quality-control department.”

The Crysta-Apex S9106 has a measuring volume of 900 x 1000 x 600 mm. As well as measuring large, one-off parts, the CMM’s generous capacity also makes it possible to inspect multiple smaller components in automated, CNC, mass-measurement routines.

“Our new Mitutoyo CMM’s ability to accurately and rapidly inspect a large batch of components has further improved our quality-control department’s efficiency levels,” says Jagelman. “Notably, our inspection staff are now able to load the CMM’s bed with multiple components, quickly recall the relevant part program and instigate a fully automated inspection procedure. On completion, we can generate a detailed inspection report relating to each component.”

For further information
www.mitutoyo.co.uk

BGF backs Sertec

BGF – a UK-based capital investor – has invested a further £4m in Midlands-headquartered automotive components manufacturer, Sertec Group, as the business looks ahead to European growth. In 2020, Sertec secured significant new contract wins in the electric vehicle (EV) and lightweight technology markets, using its engineering expertise and technology know-how. The company has also recently completed a world-class battery component assembly line in Coleshill. Sertec Group has six manufacturing sites in the Midlands, plus other facilities in Hungary, Germany and China.

For further information
www.sertec.co.uk

Alphacam licence aids PPE production

A free evaluation licence from Alphacam meant that a manufacturer could put a machine awaiting commissioning to work producing essential PPE for front-line health workers. Codem Composites had recently invested in a pre-owned Blackman & White CNC cutting machine, with a bed capacity of 2.2 sq m, to cut carbon fibre pre-impregnated with an epoxy resin. The carbon fibre serves to make components for the motorsport industry and satellite dishes.

“The machine hadn’t been fully commissioned and we had post-processing issues with the software and interface – we didn’t want to invest several thousand pounds in software immediately, given the uncertainty surrounding COVID-19,” explains managing director Kevin Doherty. “However, when we got the call asking us to cut NHS scrubs, we approached Alphacam to help get the machine up and running. Alphacam supported our efforts by providing us with a free evaluation licence.”

The software gave Codem complete flexibility and speed of production by optimising nests. Running at a capacity of around 500 full sets of scrubs a week, the Blackman & White machine cuts components for a group of volunteers in Northamptonshire to put together.

Alphacam accurately interrogates the DXF file for each of the patterns, and computes all permutations and variables.

“So rather than someone having to work everything out manually, such as what we are going to cut, how we are going to cut it, and what’s got to go where, we simply input which components we need in which sizes,” he says. “Alphacam does the rest, including helping us with the correct cutting speeds and feed rates. The first cut parts came off the machine within 24 hours of installing the software.”

For further information
www.alphacam.com

AM boost for regulated sectors

A new project at the National Centre for Additive Manufacturing (NCAM), based at the MTC in Coventry, aims to transform the use of additive manufacturing (AM) or 3D printing in highly regulated industries. Currently the adoption of AM in sectors such as aerospace is hindered somewhat by the lack of standards for part quality, reliability, traceability and process repeatability. The Daedalus project, funded by UK Research and Innovation, will help make the UK become the go-to place for forward-thinking manufacturing by enabling AM in highly regulated industries such as aerospace, space, oil and gas, and medical.

For further information http://ncam.the-mtc.org/