Ricardo begins face shield production

As a part of the national effort to provide much needed PPE in the fight against COVID-19, Ricardo has turned to the production of face shields that will be used by frontline NHS healthcare staff, as well as key workers in the care sector.

To ensure that these essential PPE items can get to NHS employees who need them as quickly as possible, facilities at Ricardo’s Technical Centres in Shoreham and Leamington Spa are being repurposed as assembly lines and logistics centres for face shields. Ricardo used its manufacturing supply chain expertise to engage with an injection moulding partner, to create a tool capable of high-volume manufacture.
For further information https://ricardo.com/

Fast and accurate tooling

A high-precision, quick-change tooling system has been launched by Dormer Pramet for a variety of internal and external turning applications. Suitable for use on multi-tasking machines, the polygon shank coupling (PSC) is a spindle interface which promotes higher productivity through reduced set-up time and faster, more precise machining, reports the company.

Dormer Pramet’s PSC achieves this performance by deploying a tapered polygon cone shank and flange surface, which supports a high degree of rigidity. With accuracy in X, Y and Z of ±2 µm, PSC holders provide a high level of repeatability. In addition, a reduced overhang length minimises vibration and runout inaccuracy for a high-quality surface finish, making it suitable for both aerospace and general machining applications.
Connected by a triangular conical structure and cross section, which uses 1/20 taper, the PSC features internal coolant channels and a steel tool holder. More than 130 items are available, including a variety of tool-holder styles, internal tools, interface types and shank sizes.
For further information www.dormerpramet.com

10,000 blades

Rockwood Composites and Leonardo have marked the 10th anniversary of their partnership with delivery of the 10,000th blade for the towed decoy on the Eurofighter Typhoon.

All parts are fully CNC machined and supplied paint-ready on a just-in-time basis. Rockwood has also supplied Leonardo with connector plates for the wing. Holly Jones, senior subcontract buyer at Leonardo in the UK, says: “Our 10-year partnership with Rockwood is testament to their ability to deliver quality composite components, consistently, when we need them.”
For further information www.rockwoodcomposites.com

Threading with enhanced chip breaking

The 108 and 114 Mini tooling systems from Horn have been extended through the addition of new inserts with GM threading geometry that is suitable for turning ISO metric internal threads. Availability in the UK and Ireland is through the German manufacturer’s UK subsidiary, Horn Cutting Tools.

Horn’s chip-breaking geometry generates short lengths of swarf, even when processing what are normally long-chipping materials and those that are difficult to machine. The swarf is easier to handle, the risk of chip build-up is reduced and ‘bird nesting’ around the tool and component is avoided, reducing lathe stoppage time and increasing productivity.
Using the 108 system, users can produce metric internal threads from M10 with pitches of 0.5 to 1.25 mm, while the 114 system is suitable for pitches up to 2.5 mm. The inserts are available in partial and full profile design. Standard, low-vibration, carbide turning tool holders from the Mini system may be used, enabling the production of high surface finishes, even on deep threads, and ensuring high process reliability.
Mini-type inserts screwed on to the face of the holder are among Horn’s core products for turning and milling applications. The tools are especially suited to internal profiling and internal grooving. Furthermore, the Mini system range offers inserts with different geometries, substrates and CBN or diamond coatings in a variety of sizes for various internal diameters.
For further information www.phorn.co.uk

Precise truck engine cylinder bores

Modern truck engines are produced at the Mercedes-Benz plant in Mannheim, where the requirements for ideal manufacturing include extremely tight tolerances for the decisive dimensions of engine blocks. Thanks to close co-operation between specialists from Mercedes-Benz, the machine manufacturer and Mapal, significant progress was made when a new production line for machining engine blocks was designed and implemented.

The engine blocks have a complex geometry and numerous key characteristics for which the highest tolerance classes must be reliably observed. Depending on the engine type, these include multiple H7 fits, various areas with accuracy specifications less than 15 µm, and chamfers with tight tolerances, including a 20° chamfer with an outlet for which an angle tolerance of just ± 0.025° must be observed.
A first line for machining these engine blocks was commissioned in 2011. When planning a second line, the persons responsible drew on their experience with the first line. The team identified the machining of the bores for the cylinder liner adapters as particularly challenging. Machining was divided into two stations: one for pre-machining and one for fine machining.
To this end, Mapal has developed complex actuating tools that are equipped with up to 20 indexable inserts, including ISO inserts and custom inserts. The actuating tools feature a tool body in monoblock design, and the HSK-160 connection shows an enlarged face surface with a diameter of 200 mm. One tool weighs a total of up to 60 kg.
Despite the connection and a tool length of 380 mm, it must be ensured that the tool has a radial run-out accuracy of 3 µm. The slides are actuated by a drawbar via an additional NC axis in the machine controller that had to be integrated in the HSK connection and suitable for the automatic tool change. This challenge was solved with a high-precision bayonet coupling that is used to couple the drawbar automatically during a tool change.
For further information www.mapal.com