When Tamworth-based Alcon Components was awarded a contract to supply the lightweight monobloc brake calipers for a new hybrid electric hypercar, the subcontractor turned to Kingsbury to supply an automated, turnkey machining cell that would produce the aluminium components.

Comprising a Hermle C32U five-axis machining centre fed with pallets from an Erowa Robot Easy 250 automated storage and handling system, the cell has already started producing calipers, as the job had previously been proved out on a near-identical cell installed in 2016. Essentially, the only difference is that the latest machine has extended tool capacity.
The hypercar has one brake caliper per wheel, the set of four requiring in excess of 24 hours to be machined from solid aluminium billets. Four operations are needed: pre-milling on another vertical machining centre, op 1 on the Hermle C32U, transfer back to the other machining centre for simple boring cycles, and finish machining on the C32U. Fully Interpolative five-axis machining of freeform surfaces accounts for less than 10% of cycles on the Hermle machine, with 4+1 and 3+2 strategies used
wherever possible.
A limited number of road-going hypercars will be produced, while a few track-only versions are also planned. Alcon is responsible for the full foundation brake system, pedal box and actuation, as well as a number of precision chassis components. When the contract has been completed, Alcon will split its ongoing production of calipers for high-performance road cars, race cars and defence vehicles between the two automated Hermle-Erowa C32U cells. A smaller C20U on the shop floor, purchased in 2007 with an Erowa automated pallet storage offset to the side rather than positioned directly in front of the machine, will then be reserved for producing prototypes.
For further information www.kingsburyuk.com

Machine shops looking to progress from three- or four-axis CNC prismatic metalcutting and invest in a five-axis facility can now consider the affordable UQ400 vertical-spindle machining centre from Wele of Taiwan, whose machine tools have been offered in the UK and Ireland since mid-2018 under a sole agency agreement with Whitehouse Machine Tools. Wele is part-owned by Japanese machine tool manufacturer, Toyoda.

Wele’s UQ400 has an installed weight of 6.5 tonnes and occupies a compact footprint of 2.95 x 2.35 m. Capable of interpolating four of the five axes simultaneously, it is intended for the five-face machining of workpieces weighing up to 200 kg (with fixture). A Fanuc 0iMF control allows an easy gateway into five-axis operations for users more familiar with this CNC system than others on the market.
The working envelope is defined by 400 x 650 x 485 mm ballscrew-driven travels in X, Y and Z, together with two rotary, hydraulically clamped axes, which are facilitated by a 360° C-axis table and a +30/-120° A-axis swivelling trunnion.
The BT40 direct-drive spindle, served with cutters exchanged from a 24-station tool magazine, offers 11 kW of continuous power (15 kW for 30 minutes) and speeds up to 12,000 rpm, or optionally 15,000 or 20,000 rpm (HSK-A63). High production output is assured by a cutting feed rate of 10 m/min, and rapids of 36 m/min in X, 24 m/min in Y and 10 m/min in Z.
Standard equipment includes chip wash-down for the table and twin augers in the Y axis, plus one in the X axis to evacuate swarf, while bed wash-down and different styles of chip conveyor are available.
For further information www.wmtcnc.com

Okuma, represented in the by NCMT, is releasing its MCR-S (Super) double-column machining centre, which is particularly suited to the machining of press dies. The machine also unites subtractive and additive manufacturing methods, allowing for process-intensive production.

MCR-S possesses a cast-iron double-column structure. Equipped with Okuma’s ‘Thermo-Friendly’ concept, any unnecessary heating-up can be prevented, while thermal deformations are compensated. When manufacturing press dies, this factor is especially important because the machining process can take days or even weeks, making it vulnerable to changes in temperature.
By using a swivel image sensor that rotates relative to the indexing angle of the tool, accurate measurements of cutting edge position can be provided, improving accuracy even further.
Okuma’s ‘Hyper-Surface’ premium solution eliminates the need for hand-finishing by creating die surfaces that are ready for use. Hyper-Surface improves surface quality by automatically detecting disturbances in the CAM-output machining data and correcting them on the CNC while maintaining the required shape accuracy.
The machine possesses a heavy-duty cutting capacity, reaching a chip removal rate of
710 cm3/min when face milling. Average continuous feed rates of 20 m/min for the X and Y axes, and 10 m/min for the Z axis, contribute to the machine’s productivity.
For process-intensive manufacturing, the machining centre is equipped with a laser that allows for additive manufacturing via laser metal deposition (LMD). This way, subtractive and additive manufacturing methods are combined in one machine, enabling manufactures to not only produce complex parts, but repair defective workpieces. The laser can also be used for surface treatments such as laser hardening.
For further information www.ncmt.co.uk

A six-axis, horizontal-spindle machining centre with a working volume starting from 4100 x 1600 x 650 mm, with options of 2.1 and 2.6 m in the Y axis, and up to 30 m in the X axis, has been introduced by F Zimmermann specifically for producing structural components in the aerospace industry.

Availability in the UK and Ireland is through sole agent Kingsbury, and in the Middle East through subsidiary company, Kingsbury Gulf.
Equipped with an integrated, expandable, patented pallet-change system that automatically loads the component into the vertical plane for machining, the FZH400 is the first horizontal machining centre from F Zimmermann, a long-established manufacturer of gantry-type, vertical-spindle machines.
A horizontal configuration harnesses gravity to allow the removal of copious volumes of aluminium swarf generated from solid billets by the 100 kW spindle. Trials have demonstrated material removal rates of over 13 l/min, due in part to linear axis acceleration at 6 m/s2, with rapid feed rates up to 60 m/min in the X axis, and 40 m/min in Y and Z.
The spindle head has three CNC axes, hence its designation M3 ABC, offering extra versatility compared with two-axis heads for executing complex programs. Movement of ±110° in the A axis, ±225° in the C axis and the addition of ±14° in the B axis eliminates the risk of singularity errors occurring in cutter paths, without the need to use avoidance algorithms.
Another patented feature of the machine is a water-cooled travelling column that does not suffer from the traditional drawback of spindle deviation as the slide extends in the Z axis.
For further information www.kingsburyuk.com

Frank Brown and Son is a Luton-based engineering company specialising in the design and manufacture of ground-support equipment for the aerospace and aircraft industry throughout the world.

The company bought its first Haas machine in 1996: the VF-2D vertical machining centre ran every day until two years ago, when the team decided to part-exchange it for a new Haas VF-2SS Super Speed.
“We certainly got our money’s worth from that original machine,” says machine shop supervisor, Andy Knight. “It was running well until its last day; it was always accurate, we just upgraded to something a bit quicker in the end.
“The machine shop has doubled in the past 20 years and, with 20 Haas machines [six lathes and 14 mills], the majority of our CNC machinery is still supplied by Haas,” he adds. “Our workload has changed dramatically in recent years. Not so long ago we were making stock packs of 10 a year, but now its 40 plus. And everything that needs machining goes on a Haas.”
The latest investment is a VF-4SS with through-spindle coolant and five-axis trunnion. “The five-axis machines are doing some really nice work,” says Knight. “They have cut our operations from six to two, which is a massive reduction. We’re producing a lot of Boeing 737 and Airbus tooling, and it’s really made a difference. It’s knocking the stuffing out of the cycle times, cutting them by a third at least.” In fact, the company has purchased four Haas Super Speed mills in the past four years. “The rapids, tool-change speed and 12,000 rpm spindle are phenomenal on the new machines,” concludes Knight.
For further information www.haas.co.uk