FEATURE ON WORKHOLDING

High-volume machining of aircraft brake clips

Aerospace is Westley Engineering’s largest market, accounting for 45% of total production by value. A notable aerospace contract involves the manufacture of rotor clips used in aircraft disc brakes. Made from aerospace-grade steel and Inconel, the components see application in both civil and military aerospace programmes.

Three years ago, Westley Engineering improved the accuracy of the manufacturing process by switching from piercing holes in the clip using press tools to drilling them on a 40-taper vertical machining centre. Although it improved precision, the new approach also increased cycle times substantially and made the process more labour intensive. So in late 2023, the company installed a Brother Speedio S700Xd1 4-axis, 30-taper machining centre, followed by a second in April 2025. Supplied by Whitehouse Machine Tools, the exclusive UK and Ireland distributor for the Japanese manufacturer, these high-speed machines have now replaced the VMC for clip production.

In partnership with Whitehouse Machine Tools, Westley Engineering implemented an automated, single-operation process on each Speedio. The new production route features custom-built fixtures with nine inclined bars, each capable of holding 36 clips. This high-density arrangement enables over 300 parts to be machined per cycle, significantly more than the flat fixtures used previously.

Cycle times have been reduced to between two and three minutes per clip, depending on the variant. For example, the Inconel version requires additional milling on the outer arms, whereas the steel variants do not. Typical batch size ranges from 5,000 to 10,000 units.

Before deployment, the process was validated at Whitehouse Machine Tools’ Kenilworth technical centre.

More information www.wmtcnc.com

Improved results with live tools from Heimatec

The desire to save time and the related cost benefits has always existed. However, in the past, lathes – or the turrets mounted on them – were limited in their maximum rotation speed, subsequently restricting the achievable cutting speeds. In order to produce higher quantities in a shorter time, attention was paid directly to the live tool and, where possible and sensible, speeders were designed and produced. Gear ratios up to 1:4 result in a speed increase of 48,000 rpm.


In the meantime, there are some machine tools with turrets that achieve higher rotation and thus higher cutting speeds. This adaptation results in higher requirements on the mounted live tool units mounted. Wear parts such as bearings and seals are more stressed and must be replaced more frequently. Likewise, when using tools that are not designed for such high rotation, there is a risk that the gears of the tools will overheat, spindles will be overstressed and, as a result, tools will be damaged.

To counteract these problems, Heimatec – available in the UK from Hyfore – has adapted some products and designed them to be suitable for extra high rotation (up to 15,000 rpm). Thus, axial drilling and milling heads – as well as radial drilling and milling heads – for selected machine manufacturers are already available with these specifications. In use by customers, these prove the design measures implemented to achieve high speeds with the predictable wear and service life.

The advantage of the Heimatec high-speed tools is that they also operate smoothly at lower rotation over the speed range available from the machine tool turret.

More information www.hyfore.com

SW Sfix for modular and automated clamping

At this year’s EMO exhibition in Hanover this September, Schwäbische Werkzeugmaschinen (SW) is presenting the new Sfix system (Smart Fixture). Sfix is capable of automatically assembling modular clamping fixtures for workpieces, enabling efficient and precise clamping even for small batch sizes.

“Especially outside the automotive industry, we see great potential for optimisation in medium- and small-series production, which requires greater flexibility and modularity from manufacturers,” says Michael Kreuzberger, product manager at SW. “To address this, our new Sfix system transforms clamping technology: through automation, it enables higher productivity even in production lines with smaller batch sizes.”

The Sfix system offers a solution to one of the machining industry’s biggest time wasters: the clamping of small- to medium-sized product series. Sfix provides a flexible solution to this challenge: it automates the assembly of the appropriate clamping technology for each workpiece – and provides users with a virtually unlimited number of clamping fixtures for a one-time investment. At the core of the system is SW’s patented Sfix plate, which features retractable pins that allow for flexible positioning of components. Various clamping modules can then be attached to these pins to build the individually required fixture.

The advantages of the Sfix system extend beyond its modular mechanical design: in the so-called S-cell, which SW is presenting at its EMO booth, the clamping fixture is assembled quickly and fully automatically. The cell is equipped with all necessary clamping components and workpiece carriers as well as a robot. Users only need to define the clamping points within the CAD model and configure the fixture set up.

More information www.sw-machines.com

Micro VC Holder provides pinpoint precision

Nikken is releasing its Micro VC Holder, a micro-tooling range designed for high precision, reliability and high-performance micro-machining. According to the company, the Micro VC Holder offers exceptional precision, balance and efficiency for industries where perfection is paramount. Whether crafting intricate components for luxury timepieces or producing highly detailed medical instruments, the Micro VC Holder ensures results with minimal runout (3 μm at 4xD) and high-speed performance up to 50,000 rpm.

Designed to support the latest generation of micro machine tools and high-speed spindles, the Micro VC Holder is available in monobloc and straight-shank variants. This versatility allows manufacturers to achieve enhanced accuracy and cost savings by eliminating the need for extended length cutting tools, which can be crucial in both watchmaking and medical applications where micro-level precision is essential.

The reduction in vibration, through in-built damping and reduction in tool wear means extended tool life and lower replacement costs – delivering financial benefits that directly impact profitability.

Furthermore, the Micro VC Holder incorporates the HSK-E symmetrical tool-holder shank, which eliminates drive slots, tooling holes and timing notches. This results in superior balance and reduced vibration, critical for maintaining flawless finishes on watch components and ensuring the tight tolerances required for surgical tools and implants. The advanced 8° collet system further enhances grip and stability, reducing tool deflection and extending tool life.

Nikken says that its Micro VC Holder proves that size really does not matter – at least when it comes to tool-holding technology.

More information www.nikken-world.co.uk

Device checks small tool holder pull-in force

OTT-JAKOB Spanntechnik, a German manufacturer of tool clamping systems for lathes, milling machines and grinders, has launched a spindle clamping force measuring device, the Power-Check Micro. A key component for preventative maintenance, it has been introduced alongside the established Power-Check 2 and Power Check Magazine, which determine the pull-in force with which a tool holder is held in a large diameter spindle taper, whether it is HSK (up to 160), BT (30, 40 or 50), SK, CAT or another type.

In contrast, the Power-Check Micro is designed to perform an equivalent job for more compact HSK E15, E16 and E20 spindle interfaces, which are mainly found on small, precise machine tools intended for high-speed cutting. Such machining platforms are typically utilised in the dentistry and jewellery sectors, as well as for the production of small parts used in electronic and medical products, precision components in aerospace and automotive engineering, and small tools and dies.

These pull force measuring units are exclusively available in Britain and Ireland through sole sales agent Gewefa UK. The company points out that the new device is pertinent to nearly all micro-manufacturing applications, where there is a growing emphasis on process reliability, condition monitoring, preventative maintenance and quality assurance.

The latest drawbar force monitoring system is of compact design, measuring just 48.8 x 43 x 41.5 mm and weighing approximately 200 g, making the unit suitable for use in constrained working areas. Mains-independent, power arrives courtesy of two replaceable lithium batteries capable of up to 1000 hours of continuous operation.

More information www.gewefa.co.uk