Editor’s Pick

Battle robots get a five-axis boost

For followers of the BBC’s Robot Wars programme, the names Sir Killalot, Shunt, Matilda and Dead Metal will be familiar as the house robots whose sole purpose is to lie in wait for competing bots and take their opportunity to destroy them.

These mean weapons are designed and built by two brothers in a small corner of their family business that is more used to manufacturing furniture castors.
Grant and James Cooper both worked for the family company of Priory Castor and Engineering in Birmingham, but as that business changed they saw a need to diversify and put their knowledge of engineering design to good use. The result was Robo Challenge, a design and creative engineering company that now works alongside TV production companies to create one-off robots and engineering concepts.
Robo Challenge employs an XYZ LPM vertical machining centre to create a range of parts from aluminium, titanium and stainless steel.
“We tend to be at the end of the process after weeks, if not months of discussion have taken place,” says Grant Cooper. “We are then asked to produce complex machines in a short space of time. For example, the four house robots for Robot Wars were designed and built in less than eight weeks, but typically we get one to three weeks to complete a project, so an efficient machine that can be used by anyone here was essential for us. The LPM with its ProtoTrak control, tool changer and large table, works perfectly for us, especially as just about everything we produce is a one-off.”
For further information www.xyzmachinetools.com

New flow line at Heller UK

More than £2m has been spent upgrading the Heller Machine Tools manufacturing plant and headquarters at Redditch, UK.

The administrative and applications engineering departments have benefitted from a comprehensive makeover, while a new customer area for machine demonstrations has been added. Most notable of all, production output of horizontal machining centres has risen by 30%.
As part of the latest initiatives, activities in Redditch have expanded into the assembly of five-axis machines (in addition to four-axis models) for world markets. As part of the expansion, Heller installed an 11-station Strothmann flow line and new logistics system for the manufacture of horizontal machining centres. At every stage of the manufacturing process, work carried out on the machines is documented, providing full traceability as required in order to comply with the factory’s ISO9001 accreditation.
For further information www.heller.biz

Smart factory set for Scotland

The University of Strathclyde’s Advanced Forming Research Centre (AFRC) has agreed a tier-one partnership with software platform BitzList – the first micro-business to sign a top-level agreement with a High Value Manufacturing Catapult organisation.

Working in collaboration, the AFRC and BitzList are developing a technological platform for the creation of a smart factory – an environment where machinery and equipment are able to improve processes through automation and self-optimisation using a constant stream of data from connected operations.
Through the partnership, BitzList will give the AFRC access to specialist Industry 4.0 software it has been working on for over 15 years. The software is designed to provide manufacturers with the tools needed to organise day-to-day operations, and for parts suppliers to streamline supply chains. This technology, which is already deployed within the manufacturing sector, can be used by customers and suppliers to request the production of parts.
For further information www.strath.ac.uk

Alitech races to success with ITC

As a subcontract machine shop, Alitech Precision is a company that is rapidly evolving, a fact credit to its aggressive investment programme, enthusiasm and love for all things motorsport. Since its inception little over three years ago, the Silverstone-based company has purchased three Haas machining centres, Open Mind CAM software, a Spinner five-axis machining centre and cutting tools from Industrial Tooling Corporation (ITC).

A recent example of the partnership between Alitech and ITC could be seen when it came to the profile machining of deep port pockets. Here, it was ITC that stepped up to the challenge with its lollipop cutters. The majority of projects undertaken by Alitech involve the complex, simultaneous five-axis machining of parts such as billet inlet manifolds, valve seats, inlet port heads, billet turbo manifolds and much more. Reaching deep into ports is a complex challenge for the machine tool kinematics, the CAM software, the cutting tools and tool holding. At the sharp edge are ITC 4101 lollipop end mills that permit Alitech to reach surfaces around corners and deep inside manifold ports.
Commenting upon the daily challenges at Alitech, managing director Darren Cudd says: “We recently machined a billet turbo manifold for a motorsport customer that required two 40 mm diameter oval shaped port holes with a curved machining depth beyond 200 mm. We used an 8 mm diameter ITC lollipop cutter necked to 5 mm that was protruding 70 mm from a slim 80 mm heat-shrink tool holder extension with a 75 mm long back-end configuration. The rigidity and geometry of the ITC lollipop tools ensure we attain an exceptional surface finish while machining at extremely productive speed and feed parameters.”
For further information www.itc-ltd.co.uk

Subcon 2018 opens this week

The organiser of Subcon (5-7 June, Birmingham NEC) has revealed that it is preparing for a bumper year with over 400 exhibitors confirmed and some 4,500 visitors expected, which would be a new record.

This year, visitors will enjoy two shows – Subcon and a brand new sister event, The Engineer Expo.
“There is going to be so much to talk about this year: from our research into the ignorance around Industry 4.0 and the importance of increasing the number of women in manufacturing and engineering leadership roles, to the presentations across our stages and discussions among the stands of more than 400 exhibitors,” says Subcon event director Gordon Kirk. “This year’s event is set to be our best yet and will give visitors and suppliers an opportunity to interact with every facet of the UK manufacturing and engineering community, maintain their competitive edge, and shape how the industry is seen from the outside.”
For further information www.subconshow.co.uk