A specialist in precision pressed parts and machined components has invested more than £100,000 in the installation of a new high-speed press line to boost capacity ahead of a raft of new opportunities. Source Engineering, which employs 32 people across its two divisions in Plympton, has leveraged the expertise of Bruderer UK for a machine to carry out the work of four conventional HME power presses.

Established in 1992, the company has gone from strength to strength, building and maintaining experience and knowledge across all aspects of its business. Source Engineering is continuing to develop that knowledge by training the next generation of engineering and toolmaking apprentices, ensuring that the company continues to thrive into the future.

Source Engineering is always looking to move forward and continually improve, whether it is product improvement or developing production processes. The firm stays competitive and improves quality by developing new production techniques, automating processes and investing in the best equipment – from EDM wire erosion machines for the tool room, through to Swiss-made high-speed/high-precision presses for the press shop.

The BSTA 200M 20 tonne stamping press from Bruderer was identified as the ideal solution for the company’s latest requirements and is now up and running at Source Engineering’s Langage Business Park facility, achieving 300 strokes per minute. This rate represents a 200% increase in production output across a range of products destined for the automotive, electrical wholesale and oil and gas markets.

Engineers at the firm have freed up an additional 500 sq ft of production space to use for the introduction of new projects, and to help Source Engineering cope with an increase in demand for its range of automation solutions.

Andy Dunkerley, chairman at Source Engineering, says: “Buying a Bruderer is like buying the Swiss watch of machines; you get unrivalled precision, speed and repeatable quality, all wrapped up in a relatively small footprint. We already had one in another part of the factory and were fully aware of its capabilities. So when it came to looking at how we optimised the factory floor space by replacing four machines with one high-speed line, we called in Bruderer’s technical experts to review the options.”

He continues: “They really understood what we were looking to achieve in space utilisation without giving up the versatility and the volumes, which basically meant we needed one machine to do the work of four.”

The Bruderer BSTA 200M high-precision, high-performance stamping press was identified as the preferred option and was fitted with a high-speed servo feeder and pallet de-coiler to help achieve precision control of material de-coiling and pinpoint pitch through the progression press tool.

Specified with a tool area of 510 x 400 mm, the machine can deliver up to 1800 strokes per minute, and is capable of handling a maximum material thickness of up to 2 mm and material width of 100 mm. The Bruderer BSTA 200M has also been equipped with ‘Press Force Monitor’, a feature which ensures protection of the press from overload. In addition, this technology limits tool damage if any stray material is pulled back up into the process – stopping the machine within a stroke, even at high speed.

Pablo Gutierrez, technical director at Source Engineering, goes on to add: “Sales are now back to pre-pandemic levels and we are looking to grow, with our ability to provide design, tooling and manufacturing all in one place driving the need for more production space. Our long-standing relationship with Bruderer UK has been pivotal in giving us a faster and more flexible machine, while also delivering capacity to install different types of presses or a dedicated assembly area to support bespoke automation work.

“There are lots of new opportunities domestically and overseas, and we are hoping to turn some of this potential into contracts that will see turnover rise by 20% over the next 12 months,” he continues.

Adrian Haller, managing director of Bruderer UK, says: “This is a perfect example of how the technical expertise of our team and the power of our presses can be combined to find a solution that does the work of four machines in one. Tolerances of manufactured process speed have improved significantly, while the ability to achieve fast press-tool changeover has been achieved due to the in-built Bruderer application of SMED (Single-Minute Exchange of Dies).

He adds: “We’ve been working with Andy and Pablo for nearly a decade and have got an excellent relationship with the technical team at Source Engineering. This was a project that really excited us as we could use our technology to provide an immediate operational solution and, importantly, a way of supporting the company with its ambitious expansion plans.”

Source Engineering, which is approaching 30 years in business, has developed new control boxes that help monitor the part as it goes through production. The company has already supplied a number of models to Bruderer UK for installation on its machines and is looking to expand its offer further over the coming year.

For further information
www.bruderer.co.uk

Although only founded in 2004, the directors at Machfab Engineering can offer more than 60 years of manufacturing expertise in all aspects of machining, sheet metal and fabrication. But regardless of experience, everyone can learn new tricks – and for this Birkenhead-based company, the learning curve has taken a new twist with investment in 3D printing and CNC machine tools from Dugard.

Servicing customers in sectors as diverse as automotive, aerospace and offshore, through to petrochemical, pharmaceutical and food, Machfab offers a complete service portfolio that includes conventional and CNC milling and turning, jigs and fixtures, breakdown and repair work, press tool manufacture, reverse engineering, prototyping, R&D, and sheet metalworking. Some of these services were not previously available.

As Machfab Engineering director Ian Hazlehurst says: “Two years ago, we had the idea to diversify the company. We’ve always predominantly been a conventional machine shop and we wanted to get into CNC machining – but we had to offer something different to everybody else. So, we went down the 3D printing route to get into additive manufacturing. We worked with the Liverpool Innovation Fund and managed to get funding from them to purchase our first 3D printer.”

The company bought a Stratasys Fortus 380mc. Explaining the reason for buying the machine, Hazlehurst continues: “We bought this machine primarily to get into prototyping for R&D work. However, if we got a project that needs final production parts, we would never be able to offer the service to manufacture those components, which is why we invested in CNC machining – to offer customers the full package.”

Another reason the company opted to invest in CNC machine tools was that it was not always competitive on batch work or small production runs of components.

“We weren’t competitive on volume work as everyone has CNC machines and we had conventional machines, which meant our production times were a lot longer,” explains Hazlehurst. “So we decided – as part of the project with the 3D printer – to invest in two Dugard machining centres.”

The subcontract manufacturer simultaneously purchased a three-axis Dugard 1100 machining centre with a rotary table and a Dugard 1000E machining centre.

“The story behind the 1000E is that Dugard actually gave us the machine as a ‘test model’ as we had initially decided to buy the larger Dugard 1100,” says Hazlehurst. “The Dugard 1000E machine was installed for our guys to learn on – and we liked the machine so much we bought it, as well as the larger Dugard 1100 machine.”
For a company that had not yet stepped into the realms of CNC machining and had a history steeped in conventional machining, the initial loan of a CNC machining centre to prepare it for CNC production goes a long way to demonstrate the service provided by Dugard Machine Tools.

Referring to the larger of the two machines and why the company chose the Dugard 1100, Hazlehurst recalls: “We wanted a solution that gave us the diversity of components that we could put on the machine. We’ve installed a 4th axis unit so we can offer additional services and flexibility. We also have a Renishaw probing system, which means we can take measurements of parts before we remove them from the machine – as certain customers asked if we could do that. Equally important is the fact that the machine has a large bed and a powerful spindle, where we can take large chunks of material off. And we can machine hard steels as well.”

The Dugard 1100 VMC provides a work envelope of 1100 x 610 x 560 mm in the X, Y and Z axis respectively, with a 1000 kg maximum table load accommodated on the 1250 x 600 mm bed. A 20 to 10,000 rpm speed capability guarantees high levels of torque throughout the speed range.

Complementing this attribute is the 24-position automatic tool change carousel and the BT40 spindle taper that permits heavy-duty cutting on a complete range of materials, including challenging aerospace-grade metals. Furthermore, both machines supplied to Machfab include a Siemens CNC, although FANUC and Mitsubishi options are also available to suit end-user requirements.

The Dugard 1000E that was initially installed as a ‘test model’ is a cost-effective VMC with similar characteristics to the Dugard 1100 VMC, which is why the company opted to keep the trial machine alongside the larger 4th axis Dugard 1100.

“Now we have the Dugard machines, we know we can make the parts and make them right,” concludes Hazlehurst. “The machines also make us competitive, so we pride ourselves on the fact that we know our pricing will be right and we will deliver on time. Our customers will always get exactly what they ask for.”

For further information www.dugard.com

When faced with the need to find high-precision, flexible measuring devices that could satisfy the challenging inspection needs of two company divisions, Stuart Hill, development engineer at AM Hydraulics, communicated each division’s diverse requirements to Faro UK and requested demonstrations of suitable portable CMMs.

In the course of the subsequent in-house demonstrations, the speed, precision and capacity of Faro’s Quantum-M 3D ScanArm proved it to be the ideal portable inspection solution for AM Hydraulics’ large components. Likewise, when measuring the relatively smaller workpieces for the company’s AM Tooling division, the recently launched Faro Gage measuring arm confirmed its accuracy specification, in addition to its quick set-up and ease of use abilities. The outcome of these successful demonstrations was an order for both Faro products.

Trading since 1978, AM Hydraulics has continuingly expanded and is now a major force in the UK hydraulics manufacturing sector. Areas served by this progressive, family owned business include aerospace, nuclear power, earthmoving, oil and gas, and wind power.

Based in a recently opened, purpose-built manufacturing facility in Birmingham, AM Hydraulics offers an all-embracing, ‘one-stop’ service. The company’s end-to-end production capabilities include milling, finish grinding and hard chrome plating. In addition to meeting challenging delivery deadlines, AM Hydraulics’ level of autonomy enables adherence to rigorous quality control standards.

As an ISO9001-accredited business and an approved supplier to many blue-chip companies, the quality of AM Hydraulics’ output is of paramount importance. In addition to undertaking final inspection routines, dedicated quality inspectors make detailed in-process checks at every stage of production. Given the size (up to 3000 mm diameter) and weight (up to 20 tonne) of the company’s workpieces, administering an efficient in-process quality regime presents a range of challenges.

Now in use at AM Hydraulics, the Faro Quantum-M ScanArm is designed to deliver outstanding levels of inspection precision in less than pristine environments, such as on the shop floor. The robust Faro product carries certification to ISO 10360-12:2016, a rigorous international measurement quality standard, and tests to IEC 60068-2 standards for shock, vibration and temperature stress relief.

In addition to performing efficient tactile inspection tasks, the Quantum-M ScanArm is able to undertake precise, non-contact scanning routines thanks to the use of its Faro Blu Laser Line Probe HD. Faro’s next generation of blue line laser technology enables five times faster scanning than previous models, even when used on complex surfaces comprised of dark or reflective materials.

When compared with its predecessor, the Quantum-M ScanArm is 20% lighter in the hand and, as it requires no warm-up time, is always ready to use. These qualities ensure improved levels of productivity by enabling operators to work longer and more comfortably.

The use of industrial-grade wireless connectivity and dual, hot-swappable batteries supports the Quantum-M ScanArm’s data-transfer capabilities and its continuous operation in remote areas of the factory floor without the need for external power.

Explaining AM Hydraulics’ improved inspection efficiencies, Hill says: “Given the size of our workpieces we chose a Quantum-M ScanArm with a 2.5 m capacity, and it has proven ideal. In addition, as it’s easily transportable and quick and simple to set-up, it helps that our operators can carry the Quantum-M ScanArm to all of our production areas and quickly put it to work carrying out detailed inspection work using its touch probe or non-contact laser probe. Although our staff are experienced in using precision equipment, given the nature of the production areas, it helps that the Quantum-M ScanArm is so tough.

“In addition to delivering the levels of speed, accuracy and capacity we sought for our large parts, the Quantum-M has significantly reduced our inspection data capture times,” continues Hill. “Staff are now able to instantly download collected data, store it directly to a computer and compare it against nominal CAD data.”

Equally challenging, although different in scale, are the inspection requirements of the business’ AM Tooling division. AM Tooling specialises in the manufacture, assembly and repair of press tools, as well as providing a jig and fixture design and manufacturing service.

“Along with accelerating AM Tooling’s inspection work and data flow, the Faro Gage has enabled us to increase our precision capabilities,” explains Hill. “Also, as it’s so flexible, the Gage has helped to lessen our reliance on hand tools, such as calipers and height gauges, and reduce the use of numerous measuring instruments spread around the shop floor. Our Faro Gage is now making a major contribution towards upholding AM Tooling’s demanding quality standards.”

As the most accurate and affordable FaroArm ever produced, the recently launched Faro Gage is suited to performing inspection tasks on small to medium size components. The intuitive and versatile portable CMM boasts a 1.5 m working volume and a volumetric accuracy of 0.022 mm. Thanks to the Gage’s performance for hard probing applications, it is able to eliminate inspection bottlenecks and greatly reduce reliance on fixed CMMs.

Says Hill: “The success of both AM Hydraulics and AM Tooling is due largely to the quality of each division’s output and their efficiency levels, which allow competitive quotes to be tendered and business to be won. To make sure that we maintain these advantages, we regularly invest in state-of-the-art production and inspection technologies.

“Our two co-located divisions share the same passionate quality culture, although given the difference in their manufactured products, each has very specific inspection requirements,” he adds. “Therefore, when a decision was taken to make a major investment in portable inspection equipment, as an enthusiastic user of previous generations of Faro products, I related each division’s inspection requirements to Faro UK.

“On witnessing detailed, in-house demonstrations of a Faro Quantum-M ScanArm and a Faro Gage, I was very impressed by the latest developments and convinced that each suggested solution ticked each division’s precision and efficiency boxes. Our two new portable inspection technologies provide us with a major advantage over the use of a fixed CMM as, along with final inspection, we are able to use them to perform in-process checks on workpieces that remain located in machine tools.”

For further information
www.faro.com

Penn Elcom, a manufacturer of hardware for flight cases, speaker cabinets and 19-inch racking solutions, has seen benefits such as faster cycle times and shorter lead times thanks to the phased replacement of press brakes with advanced LEAN-series panel benders from Salvagnini. Investment of this level reflects the company’s global status as a $60m turnover business with a catalogue that contains more than 3000 products in the field of stage technology.

“We’re the biggest manufacturer of flight case hardware in the world,” states Roger Willems, founder and chairman of Penn Elcom. “There can’t be many bands or orchestras that do not use our products. Everyone thinks we’re American, but I started the company here in the UK.”

It was 1974 when Willems founded the business in the village of Penn, Buckinghamshire, where his first investment was a pre-owned power press costing £250. But from small acorns mighty oaks grow. In 2003, Penn merged with Elcom, a US flight case specialist and the company’s primary competitor. Today, Penn Elcom has UK manufacturing sites in Hastings (where the Salvagnini panel benders are located) and Tyne & Wear, as well as subsidiaries in 15 countries worldwide.

Among the specialisms at the Hastings facility are products for 19-inch racking systems. These units are essentially standardised frames or enclosures used extensively in stage technology for mounting multiple electronic equipment modules. The 19-inch racking products manufactured on site include cabinets, enclosures, shock-mount systems, rack strips/rails, shelves, drawers, panels and doors, all of which require folds. Until recently the company relied on a selection of 10 press brakes to undertake bending operations, but since making the transition to its first of four Salvagnini panel benders in 2017, the site has achieved major advances. So what prompted the switch?

“The manufacture of 19-inch racking solutions at Hastings commenced about seven years ago as we were having quality issues with products imported from China,” explains Willems. “We had some high-end press brakes from reputed manufacturers on site, but as demand grew, particularly for large panels, it became more challenging. For example, if you take a steel panel that’s 1.5 m tall, weighs 15 kg and contains 15 folds, it is physically difficult to manipulate it efficiently.”

Willems had long-known of Salvagnini panel benders, but always thought these advanced machines would be beyond his budget.
“However, one night I was on the internet looking at panel benders and curiosity got the better of me, so I made my first enquiry for a Salvagnini,” he explains. “It struck me as quite a big leap from a press brake to a Salvagnini, akin to replacing a two-seater propeller aircraft with a jet. And yet, when I learnt the price range, I was pleasantly surprised. I subsequently sent three products to Salvagnini that were proving difficult to fold using our press brakes. One of these products – a cabinet corner post – was about 2 m in length, 2.5 mm thick and had 8-10 folds. It necessitated three lifts on a press brake, so our existing cycle time was around 15 minutes, and we had quite a high reject rate.”

The trials showed that a Salvagnini panel bender could fold these products in just 50 seconds, prompting Penn Elcom to invest in its first machine.

“That was in 2017, and we now have four Salvagnini LEAN-series panel benders at Hastings, as well as one in China,” says Willems.

The Hastings site houses a Salvagnini P1, (Mini Panel Bender with a bend length of 1,250mm) and three P4lean automatic panel benders. The latest P4lean arrived in February 2021. Of the 10 press brakes owned by the company prior to the panel bender era, only three remain on site.

“Finding the skills to run press brakes is not easy, so the Salvagnini machines have also helped in that regard,” says Willems. “All of our panel benders run 24/7, with typically one operator looking after two machines. Their reliability and repeatability has been outstanding from the start – we have zero rejects – and I can see us adding more in the future.”

The Salvagnini P4lean panel bender natively combines productivity with its automatic bending and handling cycle. Process flexibility is inherent thanks to universal bending tools that automatically adapt to the panel geometry in-cycle, without machine downtime or manual re-tooling.

With its advanced cycles, a machine such as the P4lean completes an average of 17 bends per minute. At Penn Elcom, some of the Salvagnini machines feature a number of options that boost capability even further. The CUT option, for example, enables the automatic cutting of different profile lengths, materials, thicknesses and shapes from a single blank, making separation cuts after each sequence of bends.

The company has also taken a special V-score option, which can help deliver a tighter outside radius, as well as a special narrow blank-holder for the P-tool that can help process smaller parts deemed not possible on panel benders.

“Our operators absolutely love the Salvagnini machines,” says Willems. “I’ve been in the manufacturing sector for 50 years and I have to say Salvagnini panel benders are easily the cleverest machines that I have encountered. If I didn’t know better I would swear there is a little person hidden inside turning the metal around. We have visitors come in who are completely mesmerised.”

Willems suggests that if he had remained with press-brake technology his current lead times for cabinets would be as high as 16-20 weeks, with little potential to produce samples.

Samples and prototypes are an important part of business at Penn Elcom as the company is constantly developing new products to help spur further growth. A good example is DoorJammer, a portable door security device. Ever laid awake at night in a hotel room worrying about security? DoorJammer is the solution. Willems even presented the device on BBC television programme Dragons’ Den in 2017. DoorJammer is now a fully incorporated company within the Penn Elcom Group.

Another example is the PBX1 parcel box, offering a secure solution to unattended parcel delivery.

“The PBX1 is already selling in good numbers but if, as expected, it starts selling in really high volumes, we would sink without the Salvagnini panel benders,” says Willems. “We’ve learnt to take advantage of opportunities when they present themselves, and the Salvagnini machines allow us to do that. You can’t be a pioneer in industry if you don’t take risks.”

For further information
www.salvagninigroup.com

Decommissioning legacy nuclear waste silos on the former UK power generating site at Sellafield requires the machining of large numbers of ‘bins’ to close geometrical tolerances, thus ensuring they can be stacked safely. These bins are three-metre-cube, double-walled, box fabrications that are highly resonant and, to make their production even more difficult, are made from 6 mm thick duplex stainless-steel plate that tends to induce vibrations during milling.

One of the firms leading the Sellafield decommissioning work, Stillington-based Darchem Engineering, had been taking delivery of machined bins from Newcastle-based contract machinist BEL Engineering since 2017.

CEO Jonathan Lamb says: “We wanted to increase productivity but realised that further improvements to the machining process were impossible using conventional machinery and fixturing. When we tried to raise the speed of machining, chatter resulted and it was difficult to hold tolerance. So we engaged with Kingsbury to develop an entirely new machining concept in respect of both work holding and metal cutting, to improve cycle time and hence increase production rate and reduce cost.”

It was not an exercise for the financially faint-hearted. The two companies invested £500,000 in researching and developing an optimal solution for machining two variants of waste bin, known as a PFCS (Pile Fuel Cladding Silo) and an MSSS (Magnox Swarf Storage Silo).

Richard Kingsbury, MD of Kingsbury, says: “Duplex will seek out any weakness in a machining system. We considered every conceivable source of vibration, from the machine bed to the column, guideways, spindle, spindle-tool interface and cutting tools, including their grade and geometry.

“We then turned our attention to a forensic analysis of how best to fixture the bins and it was here that we achieved a breakthrough,” he continues. “By inflating five airbags between the fixture and the box and five more inside the workpiece itself, we managed to muffle the entire unit so it could be milled at high speeds and feeds without vibration. A final piece of engineering involves hydraulically rotating the 12 swing clamps around the face of the fixture – one by one – out of the way of the approaching cutter so that at any time 11 are engaged to maximise rigidity.”

To understand the natural frequencies of the MSSS bin, the company performed modal analysis in 12 different but repeatable locations around the fabrication. A tap test on a fully fixtured bin, with 32 touch clamps and three push clamps engaged – in addition to the 12 swing clamps and with the internal and external airbags inflated – showed that the vibration amplitude fell to below 0.1 g in under 17 ms on average. That is much less time than the four hundredths of a second it takes successive inserts on an eight-tooth milling cutter rotating at 176 rpm to engage with the metal being machined.

The agitation induced in the material during the cutting process has therefore completely dissipated in the elapsed time between one tooth engaging with the workpiece and the next, an outcome that is impossible to achieve under conventional clamping conditions. This solution prevents any resonance occurring and avoids amplifying vibration, thus eliminating chatter and consequent dimensional inaccuracy and poor surface finish. In effect, the resonant frequencies of the bin are now altered to such an extent that the hollow workpiece has properties similar to those of a solid cube of metal.

The project started in March 2018. A Taurus 30 machining centre from one of Kingsbury’s principals, Waldrich Coburg, was the chosen machine-tool platform for the project, and final trials took place at the manufacturer’s factory in Germany in late 2019 and early 2020. Lamb witnessed these trials and was convinced it would save cost and help Sellafield hit its box production rate as legacy nuclear material extraction ramps up over the coming years.

In mid-2020, the UK’s Intellectual Property Office granted Kingsbury an industrial patent covering the design of the novel fixturing system, based on its ability to damp the structures during milling.

The machine has a cast-iron base and incorporates a static column and moving table, a configuration that lowers the centre of gravity and increases stability. The 400 x 400 mm cross section of the ram provides the rigidity needed when machining the lower part of the component at maximum extension.

A hydrostatic guideway with a film of oil between the slide and moving assembly supports each axis. Irrespective of speed and applied load, the distance between the faces remains constant, while the system distributes an unchanging volume of oil to further help suppress vibration. The spindle employs a large bearing pack and an HSK125-B tool interface, providing excellent rigidity and machining capability.

The solution developed for the MSSS box applies equally to the MSSS skip and the PFCS box, each of which takes advantage of its own fixture, complete with airbags. Automation on the Taurus 30 sees two fixture assemblies capable of holding six different part variants for both boxes. It means that a complete ship set of parts needed for all MSSS and PFCS bins are fixtured across the two pallets. While one pallet is within the machining area, the operator has free access to unload and then reload to the fixture assemblies on the other pallet, so downtime is limited to the pallet changeover time.

Lamb concludes: “I’m certain that the combination of Kingsbury’s patented fixture solution and the Waldrich Coburg Taurus machining centre will provide Sellafield with a reliable and cost-effective long-term solution for the manufacture of the MSSS and PFCS boxes.”

For further information
www.kingsburyuk.com