Alpine F1 Team’s recent investment in eight Mikron MILL P 500U five-axis machining centres has had a dramatic and positive impact on the productivity and efficiency of its manufacturing operations. The machines – four with integrated automatic pallet changers and four without – are now operational at the F1 Team’s manufacturing facility in Enstone, Oxfordshire. These eight MILL P 500Us replaced six Mikron HPM 450U five-axis machines that were acquired in 2016. Whilst still performing satisfactorily, the HPM 450U’s days were numbered.

Ian Pearce, Alpine F1 Team’s head of supply chain, says: “The Mikron HPM 450Us are good machines but changing situations and circumstances within our own manufacturing operations dictated that they needed to be replaced as a matter of some urgency.”

The arrival of the new machines has enabled Alpine F1 Team to take advantage of fast rapids (61 m/min) and 1 G acceleration/deceleration rates, as well as gantry-type construction and a trunnion rotary tilting table (with tandem support on its tilt axis).

Front uprights are among the parts now undergoing machining on the MILL P 500Us.
Says Bruce Foster, metallics production manager at Alpine F1 Team: “The uprights are primarily 3+2 machined from solid aluminium, with full simultaneous five-axis machining taking place when and where appropriate and beneficial. Cycle times are about 12 hours per upright, while geometric tolerances across the part are 10 µm or better, along with Ra 0.2 µm surface finish.”
In addition to the front uprights, the MILL P 500U machines produce the cars’ hydraulic manifold from (solid) aerospace-grade aluminium to exacting tolerances. Over 85% of the material is removed during the roughing process, leaving a complex part exhibiting a number of delicate and intricate features.

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Injection mould tool specialist, Swindon-based Metalite Engineering, has recently added to its plant list with the arrival of a Quaser five-axis UX500C machining centre and a 10-pallet Erowa Robot Easy 250 pallet loading system. Supplied and integrated by the Engineering Technology Group (ETG), the new investment is adding significant capacity to Metalite with its unmanned machining capability.

The UX500 is primarily for medical sector work, although Metalite is also highly regarded for its ability to serve the aerospace, automotive, Formula One, food packaging and horticultural industries. In total, the machine has 60 tools and a 15,000 Maxia spindle with a face and taper dual-contact system. Additionally, the UX500C has rigid knuckle-type axis rotation to provide full machining access around the component. Metalite needs this flexibility and precision as it is making parts that extend from small medical components with 5 µm tolerances, up to large tool steel die parts. For this reason there is a crane on the automation system to load larger billets.

ETG’s Steve Brown says: “The partnership between Quaser and Erowa goes a lot deeper than what is here in the UK. Both companies have a technical partnership and that is rolled through to us at ETG. So, we are the distributor for Quaser machines, and we have great support from REM Systems that supply the Erowa system. When we enter into a package together, we can tailor the solution to meet the needs of the customer.”

The success of this installation has already seen Metalite order a second system that will be applied to a three-axis vertical machining centre, where the robot loading system will incorporate four pallets.

For further information
www.engtechgroup.com