Established in 1982, Daventry-based Hi-Force is a UK specialist in hydraulic torque wrenches, bolt tensioners, jacks, crimpers and cutters, as well as nut splitters and flange spreaders.

Having previously subcontracted its component production, the company decided in 2008 to open its own machine shop and bring the majority of its metal cutting in-house.

The first machine-tool purchases were a five-axis machining centre and NL3000 lathes from DMG Mori, closely followed in 2010 by an NT 4250 turn-mill centre. Earlier this year the latter machine was replaced by a NTX 3000 seven-axis multi-tasking version. More than 80% of the 20 CNC machine tools on-site are from this supplier.

Chris Dickinson, group operations director, says: “The previous NT 4250 gave us remarkable service, but we thought it prudent to upgrade to the latest model from DMG Mori, which incorporates newer technology, provides greater flexibility and is more economical to run.”

The primary reason for buying the former turn-mill centre was for the production of aluminium housings used by higher torque tools in the Hi-Force product programme. However, the replacement machine is cutting a variety of materials, mainly aluminium but also alloy steels including EN24T and EN30B in an annealed condition. Some 100 tools in the magazine provide flexibility when setting up a new job, as the required cutters are normally already present.
The manufacturer’s relationship with this machine-tool supplier has grown over the years. Equipment from other suppliers has been considered along the way and, indeed, some has been purchased. However, for top-end production plant, Hi-Force has decided to standardise on DMG Mori due to the reliability of its machines and the quality of service.

For further information www.dmgmori.com

Despite starting out more than 25 years ago, Dudley-based TWP Manufacturing only opened its CNC machine shop at the beginning of 2019 to produce in-house most of the components needed for its proprietary products.

Vertical machining centres and a single-spindle, fixed-head bar auto are to be found on the shop floor, but in May 2020 the company bought its first sliding-head twin-spindle lathe, a 20-year-old Citizen Cincom M32 equipped with an Iemca Boss 432r bar feed. The machine was originally sold in 2000 by the Japanese manufacturer’s agent for the British and Irish markets, NC Engineering, which in 2008 became a wholly-owned subsidiary, Citizen Machinery UK.
Phil Stanley, a director of TWP Manufacturing, says: “The speed and surface finish we are achieving are just incredible, and the fact that there is no operator intervention means we’re able to implement lights-out production, which we are looking to do later this year.”

In the first few of months of operation, the Cincom M32 was devoted to large-volume production of one particular component, but another four part numbers have now been added. All are machined from 1” hexagonal steel bar, and annual production will exceed 200,000.

Pre-sales time studies and cutting trials carried out by Citizen Machinery UK showed that all five components could be produced within tolerance at the required speed. The calculations were performed following a visit by managing director Edward James and regional sales engineer Warren Garratt to the Dudley factory, during which the company was advised on how best to proceed with its in-house turned parts production strategy.

“Even though the machine was 20 years old and we bought it independently on the second-hand market, from the outset Citizen have been behind us,” says Stanley.

For further information www.citizenmachinery.co.uk

Identifying a business opportunity is one thing, but turning an opportunity into a profit centre is quite another. When the founder of Wuxi Fortune Technology decided to pursue manufacturing certification with one of the world’s largest automotive technology powerhouses, he chose Tornos as his partner for turning machines and the respective application and process support.

Managing director Jian Wang says: “We saw there was a place for high-end turned part production. To fulfil the great potential this opportunity represented we needed high-end, reliable and effective turning machines that would guarantee our ability to serve automotive customers. We knew that using advanced production equipment and technologies would help identify us as an excellent supplier, allowing Wuxi Fortune to deliver parts earlier than expected and even become an exclusive supplier of certain components.”

Jian Wang specifically wanted multi-spindle turning machines to gain higher efficiency and product consistency, while reducing manpower and production costs.

Wang visited and compared several turning machine manufacturers before purchasing from Tornos. Today, there are two MultiSwiss 6×14, one MultiSwiss 8×26, an SAS 16.6 and a MultiSigma 8×28 for small precision parts on site at Wuxi Fortune.

“Our Tornos machines are reliable and efficient,” he says. “Tornos provides completely integrated services, application knowledge, machine maintenance, training and spare parts to the Chinese market.”

Collaborating with Tornos helped pave the way for Wuxi Fortune to become the exclusive, worldwide supplier of a diesel injector pin shaft to a leading automotive technology player. The 23 mm long part has a maximum outer diameter of 9 mm and a minimum groove diameter of 1.3 mm, and requires a tolerance of ±0.03 mm on the outer diameter.

For further information www.tornos.com

An Eastleigh-based precision manufacturer recently turned to Yamazaki Mazak for the installation of new machinery in a challenging four-week timeframe following a project win.

The swift installation and commissioning of a Mazak HQR-200MSY CNC turning centre has enabled GW Martin & Co to expand its machining capacity and fulfil the company’s strong order book.

The machine’s two-turret, two-spindle set-up enables reduced cycle times and, when combined with the long Y-axis stroke, high-accuracy milling. Bar feeders, workpieces unloaders and robots can be integrated if required.

“Having worked with Mazak in the past, we were aware of their reputation for supplying quality turning centres,” says Richard Blake, business development manager at GW Martin. “So, when we required an automation-capable solution at short notice that could machine high-quality components in large volumes, we knew where to turn.

“Our previous experience with a Multiplex W-200Y meant we were fully confident that Mazak could adapt the HQR-200MSY to suit our existing processes,” he continues. “Bearing in mind the time pressures of the project, this was absolutely vital. Yet as we expected, even in such a short timeframe, the installation was completely seamless and risk-free.

“While this all sounds very simple, it really isn’t – Mazak’s adaptability and applications engineering proficiency was already known to us. We really appreciate how they were able to help us react quickly to our project win and, following this success, we have ordered another Multiplex W-200Y.”
Alan Mucklow, managing director UK and Ireland sales and service division at Yamazaki Mazak, adds: “The installation of GW Martin’s HQR-200MSY is a perfect example of how Mazak can assist organisations working in the fast-moving general subcontract sector.”

For further information www.mazakeu.co.uk

Motor racing is in the blood for Jeremy Welch.

His great grandfather built the first six-cylinder engine ever made in the UK (in 1906) and went on to build Brook Marine racing engines with notable success (world champion in 1921). Jeremy’s father founded Denis Welch Motorsport over 40 years ago and the company has had notable success in the UK, Europe, Australia and the Far East.

While building cars it became obvious that older models needed new components, as the originals were no longer available. The company supplies replacement performance parts for classic cars, restores and prepares ex-works cars, and specialises in Jaguar E-type and Austin Healey models.
Three Haas lathes, a UMC-750 five-axis universal machining centre and a VF-4SS super speed vertical machine have been added in the last few years.
“Having our manufacturing in-house has made a massive difference,” says Welch. “We’ve expanded our range considerably and can now control our own processes and quality.

“The training has been tremendous,” he continues. “I’d never written a program, but with Haas’ help I jumped straight on the five-axis machine. We do mainly 3+2 machining, which enables us to use fewer fixtures, and most programming is completed manually at the control using the Haas G254 dynamic work offset function. One of our operators had never used a CNC, but after training with Haas he now writes programs on our Haas ST-25Y lathe using Y axis and live tooling.”

The latest acquisition is a Haas ST40 turning centre, which is currently machining period magnesium wheels and uprights for race Jaguars.
“We bought the machine especially for this job and it’s been fantastic,” concludes Welch.

For further information www.haas.co.uk