ITC makes latest Widia Novo available

Widia Novo – the digital process planning system – has been enhanced with newly designed elements to enrich content and continue streamlining machine shop processes.

Availability in the UK is via Industrial Tooling Corporation (ITC). Among many capabilities, Widia Novo technology can supply a quick turnaround quote on modified standards of solid drills. Recently added to the Novo platform is the quoting of modified drill sizes, and an improved search engine and channel connections.
“Novo can supply a quick turnaround [in minutes] quote on solid drills modified against the standard option,” says Katie Richardson, Novo director of program management. “We’re continually adding new internal support systems that make finding the right tool even easier. Just tell us what you’re looking for and Novo can quote it, with expected delivery – fast.
“The search engine is always being fine-tuned for improvements,” she adds. “We took the ranking function of ‘Novo Advise’ and applied it to our product search so that the system can now rank the hundreds of turning inserts that fit your tool holder by performance and value. Machine shops can quickly choose the most effective tooling package based on performance, availability, price or whatever parameters they choose.”
Tens of thousands of tools are combined on Novo with 90 years of process knowledge into a cloud-enabled digital knowledge stream that interfaces with CAM packages, pre-setters and a growing number of technology providers. Responding to user questions, Novo defines machining sequences, selects and ranks the best tools, builds tool assemblies, downloads CAD models for simulations and process planning, and obtains application parameters that include speed/feed recommendations and inventory availability – all in minutes.
Recommendations for tooling can be further optimised for a customer’s specific machines and conditions.
For further information www.itc-ltd.co.uk

‘Factory in a Box’

Experts at the Manufacturing Technology Centre (MTC) in Coventry have developed a demonstrator to show businesses how they can grow through the adoption of smart manufacturing technologies and processes.

Created by the MTC working alongside the University of Birmingham, Loughborough University and a team of industry partners, the ‘Factory in a Box’ is an industrial scale demonstrator. A formal launch is planned by the MTC on 13 March. Manufacturers are invited
to attend the free event and learn how their businesses can benefit from the adoption of a smarter, more digital approach.
For further information https://is.gd/owihuq

Engine plant gains from boring control

Rigibore says that an engine manufacturer has gained total control over its boring processes thanks to the introduction of the company’s automated boring tool compensation system, Zenith.

The system was selected for its ability to make compensations automatically from measurement data to an accuracy of 1 µm on diameter. Maintaining much closer machining tolerances on crankshaft bearing journals not only enhances the quality of the finished component, but has a direct impact on engine efficiency and emissions.
The concept was to produce line boring bars with five semi-finish cartridges set 0.1 mm below nominal, thus allowing five ActiveEdge finish cartridges to machine all journals in a single pass. ActiveEdge line bars were automatically compensated to nominal from data provided by offline gauging that was transferred to the machine control as part of the Zenith closed-loop system.
Before installing ActiveEdge tools, the customer carried out verification checks to confirm that each cartridge could be adjusted independently in increments of 0.001 mm on diameter. With this ability confirmed, an extended live cutting trial was instigated. The trial took place on a twin-spindle machining centre, with each spindle machining 946 crankshaft bores over a 24-hour period, so 1892 in total. In this time, not a single bore was out of tolerance thanks to ActiveEdge’s intervention. The finished bores had a mean diameter of 52.965 mm with a tolerance of ±0.015 mm. During the test period, bore sizes were maintained within a variance of just 2 µm.
Prior to installing the tooling, the process of ensuring nominal size before the production run took 45 minutes on average. In contrast, Zenith allows automatic, individual cutting edge compensations to be made with the tool located anywhere in the machine, completing the setting process after an insert change within a matter of minutes.
For further information www.rigibore.com

Largest-ever graduation at AME

The UK’s first ‘Faculty on the Factory Floor’ celebrated its largest graduation recently, when 29 students received their BEng and MEng qualifications.

A joint collaboration between Coventry University and Unipart Manufacturing, the Institute for Advanced Manufacturing and Engineering (AME) saw its second cohort graduate in style, with many of the industry-ready engineers going into high-profile jobs at the Manufacturing Technology Centre (MTC), Wipac Ltd, Precision Castparts Corp and Unipart.
Marking a successful four years in operation, the initiative was designed specifically to give young people the opportunity to learn on real-world manufacturing projects. Over 100 students are now currently working their way through the hands-on course at AME, aided by a specially compiled textbook that is linked directly to what ‘first’ and ‘second’ year students will be trained on.
For further information www.ame.co.uk

Casting light on first-stage aluminium machining

In order to boost the first stage roughing operation on newly cast aluminium parts for the automotive industry, Sandvik Coromant is introducing its M5Q90 tangential milling cutter.

Automotive – Milling – Aluminium – Machining example

Designed to complete ‘cubing’ (first machining of faces after casting) in a single operation without creating burrs, the new tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal removal rate and an increased number of parts per insert.
“To enhance efficiency, our new M5Q90 tangential milling cutter features fully engineered cutter bodies matched with dedicated PCD insert geometries that feature a positive cutting angle to reduce cutting force and load on the machined component,” explains Emmanuel David, global automotive product manager.
M5Q90 cutter bodies are designed according to customer specifications and hence meet the requirements of high-productivity machining – the tool can operate in high-speed conditions in excess of 20,000 rpm. However, all cutter bodies offer the same design of tip seat, coolant channel, lead angle and rake angle. Inserts are always kept in stock.
Aluminium cylinder heads and engine blocks will be among the principal components to benefit, typically at automotive foundries or tier one/two suppliers. By way of example, the cubing operation on a cast cylinder head would involve machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2500 m/min and feed per teeth of 0.20 mm. Users also benefit from high-precision coolant channels that provide the option for either emulsion or MQL application.
For further information www.sandvik.coromant.com