SUBCONTRACTING NEWS

Subcontractor progresses to five-axis machining

In its 20,000 sq ft, purpose-built factory in Hayes, near London Heathrow airport, subcontractor Wellington Engineering uses 45 CNC machine tools to produce parts for sectors as diverse as aerospace, medical, semiconductors and cryogenics. The latest machine to arrive on the shop floor isa Hurco VC500i machining centre.

Owner and managing director Daimon Wellington says: “We recently adopted a strategy of looking to take on more complex prismatic machining work and had already identified a number of contracts. It was just a question of finding a suitable machining centre.Full five-axis capability was the next step up for us in terms of technology and, as we use a lot of Hurcos, we decided to source our first true five-axis machining centre from them.”

The cantilever-type VC500i is ergonomic for easy operator access, has a 520 x 450 x 400 mm working volume and a ±100° swivelling trunnion carrying a rotary table, suitable for machining five faces of a component in a single set-up. It reduces the number of separate operations needed compared with using the subcontractor’s three- axis machines, including those fitted with single- or two-axis dividing heads.

Wellington says: “Our other machining centres were taking too long to produce the increasingly complex components. Productivity drives profits and we’ve had excellent results in this respect since the five-axis Hurco arrived. Parts come off much quicker and we’re not tying up the capacity of our other machines and their operators. Also there are far fewer issues with workholding and there is less deburring and hand fettling, all of which saves time.With five-axis strategies, jobs are coming off more economically in shorter cycle times.”
For further information www.hurco.co.uk

PRECISION ENGINEERING FIRM TAKES QUALITY CONTROL TO NEXT LEVEL

Much of subcontractor Driven Engineering’s turnover comes from Formula One, although the cost cap imposed on teams over the past couple of years has reduced it somewhat, leading to a greater focus on aerospace, automotive and general engineering work. Owner Ray Harris has historically machined mainly jigs, fixtures and moulds for Formula One teams, which were telling him that to break into the supply of parts for race cars, he would have to improve his component inspection procedures and quality reports.

British CMM manufacturer LK Metrology was a beneficiary of those conversations, as Harris placed an order for one of the company’s AlteraC 10.7.7 CMMs. During its build at the Castle Donington factory, the machine was reduced in height by about 100 mm so that it would fit through the entrance to Driven Engineering’s latest factory unit in Havant and sit comfortably within a new quality room. As part of the deal, LK Metrology supplied a single licence of PolyWorks Inspector software, which is swappable between the CMM and an articulated arm bought in 2020 when Harris worked at a previous location in Portsmouth.

He says: “LK seems to be one of the metrology industry’s best-kept secrets. I had not come across them before, but our local calibration company and inspection equipment supplier, Mech Metrology & Power Tools, introduced me. Although LK is a sizeable operation that is celebrating its 60th anniversary this year, with a factory in Derbyshire and a worldwide customer base, it has a small-company feel. I got the impression that I’d receive good support and back-up, which so far has been the case. In addition, the CMM is well-built and the software provided is easy to use, including on the portable arm.”

The step up to CMM metrology immediately brought in extra Formula One work, mainly prismatic machining on three Hermle five-axis, high-speed machining centres, two of which are fitted with automatic pallet storage and retrieval systems for automated, 24/7 operation. Parts produced are typically for hydraulic manifolds as well as the race car front and rear wings and floor. The company processes a lot of titanium, plus stainless steel, aluminium and some engineering plastics. Unlike jigs and fixtures, which have fairly open tolerances, the latest parts have drawing tolerances down to 25 µm true position, which is impossible to check using the portable arm. The CMM, on the other hand, is able to measure features an order of magnitude smaller, so is easily capable of completing the inspection tasks.

During programming in PolyWorks, Harris simply picks the features and profiles he wants to inspect. The software then automatically sequences the points for the most efficient inspection routine, including all axis movements, head rotations and collision avoidance strategies. He says the software is particularly easy to use and ideal for someone new to CNC CMM operation. The system captures data both by touch-probing discrete points and tactile scanning using a Renishaw SP25M probe. Vastly more data is generated in a shorter time compared with touch-trigger probing only, enabling faster inspection and hence improved quality control. It also allows the population of more comprehensive reports with richer information on the accuracy of freeform areas on components, as well as dimensions. The PolyWorks software is able to present this data flexibly in a form that the customer prefers and is able to understand easily.

The pre-existing arm was supplied with a touch probe and a laser scanner, but now is used exclusively with the latter sensor for speed of operation when inspecting, for example, one in five of a batch of 920 aluminium mould tool halves having a complex profile, machined for the aerospace industry. On the other hand, LK Metrology supplied the CMM with tactile probing capability only, although it was prepared for laser scanning with a view to adding that capability in the future.

Before he invested in the machine, LK Metrology invited Harris to visit its Castle Donington factory to see a demonstration of an Altera 10.7.7 inspecting one of his components. It was fortuitous, as he was due to race at the Donington Park motorsport circuit nearby, having recently re-entered the sport by driving a GT car in the British Endurance Championship in early 2022. Unfortunately the Donington fixture was cancelled, so to save him the 350 mile round trip, he sent a water system for a Formula One car together with the CAD model to the factory by courier and opted to view the demonstration online. LK showed two ways of inspecting the component, first by touch-probing to orientate it on the granite and then laser scanning, and secondly using an SP25M to probe and touch-scan the part.

Suitably impressed with the latter metrology process, he decided to make the investment in the CMM and PolyWorks, whose ease-of-use is greatly helping his inspection productivity. Programming, due to the level of automation provided by the software, can take as little as 10 minutes, depending on component complexity and, unlike when using an arm, can be done in advance from the CAD model.

Installation of the CMM has opened up a number of different avenues, as availability of advanced metrology makes new business is easier to win, especially tight-tolerance work. Additionally, Harris has now bought a Ginetta GT race car to hire out for events and intends to start manufacturing a proprietary range of parts for it, such as uprights, bearing supports, axle extensions and drive shafts. The ability to control quality on the LK CMM to a higher level than previously possible will also enhance this new enterprise.
For further information www.lkmetrology.com

Start-up invests in MACH MDS 845-8T mill

MACH Machine Tools has supplied PMR Developments & Engineering, a precision subcontract specialist start-up, with a new tool-room mill. Now in situ at the company’s Hereford facility,the three-axis MACH MDS 845-8T features theDynaPath WinDelta CNC.
The MDS 845-8T is the most recent machine tool investment made by PMR in its three-year history and has taken its place alongside a new mini mill and a pre-owned two-axis lathe.

PMR’s new MDS 845-8T machines a range of precision components, including injection mould tool inserts and associated parts for a number of customers in the automotive and medical sectors, as well as new and replacement industrial equipment parts.These parts, typically machined in small volumes from a range of different materials, are characterised by their tight geometric and dimensional tolerances, and their high surface finishes.

To meet lead times and ensure that PMR achieves its machining contract requirements on time and in budget, the company regularly pushes the MDS 845-8T’s capabilities to the limit in order to reduce part cycle times.Where feasible, PMR deploys high material removal rates involving extended depths of cut and optimised speeds and feeds.

Says William Homes, PMR’s owner and director:“Our investment in the new MDS 845-8T has significantly increased our machining capacity and capabilities. The machine is powerful, fast, accurate and flexible and, although classified as a ‘tool-room mill’, such is its technical specification and processing capabilities that it’s much more production-oriented.”

He adds: “The versatility and flexibility of the DynaPath control system are also impressive. “Straight-off-the-bat, we liked the control’s large 15.6” LED touchscreen, its clear and logical navigation, and its simple-to-use and understand menus and operation screens, which all help reduce set-up times and prevent input errors.”
For further information www.machmt.co.uk

700% growth in three years in partnership with XYZ

James White joined NSK Precision Engineering in 2015 and took the company over in 2019, making a new CNC machining centre his top priority. His research led him to invest in anXYZ 750 LR with 750 x 440 x 500mm travel, Siemens 828D control (with optional ShopMill), and linear rail technology for fast acceleration and deceleration rates.

“XYZ Machine Tools listened to where we wanted to take the business, asking the right questions, showing that they understood how our company works,” he says.“They also came up with an attractive solution to get our CNC machining capacity started. We already had a 1994 XYZ turret mill with ProtoTRAK control, which is used daily, so this gave us extra confidence in our decision.”

Taking over NSK Precision Engineering, which has been in operation since 1995, was a steep learning curve, figuring out how to manage both the workforce and the day-to-day administration of the company. Additionally, White relocated the company from its previous 1500 sq ft factory to a new 10,000 sq ft site near Reading, while growing turnover by 700% and increasing his workforce from two to seven.

“Previously, we were subcontracting a lot of work to local companies,” he explains.“Investing in CNC has enabled us to take this work back in-house, which gives us more control over quality and delivery while at the same time improving our profit margins. At the old factory, we were limited for space, restricting which XYZ machine we could choose. With the new factory and the increase in workload we’ve been able to make a further investment in a XYZ 1000 LR with 4th-axis rotary table, Siemens 828D control with the ShopMill option, expanded 24-station tool carousel and a swarf conveyor.”
For further information www.xyzmachinetools.com

VMC makes low-cost jobs financially viable

Many prismatic machining contracts ideally take place on a five-axis machining centre, which enables components to be produced cost effectively. A problem arises, however, if the parts do not command a high selling price.

Subcontractor G&J (CNC) Services in Paddock Wood has apparently found a solution: the Leadwell V-30iT 3+2-axis BT40 machining centre from WH-Lead, which says the entry-level price of less than six figures belies the five-axis machine’s extensive capabilities. According to G&J (CNC) Services, the hourly rate that the subcontractor charges based on the investment allows the efficient production of less complex prismatic components at prices which compare favourably with those quoted by competitors in low-wage countries.

The company’s owner Charlie Naismith says: “Depending on the value of the parts being machined, which is normally down to their complexity and the material used, you have to make sure the figures add up. Much of our throughput is fairly simple 3+2-axis work in mild steel and aluminium that customers will not pay a premium for, so the Leadwell machine is perfect.

Continues Naismith: “We actually use it in three-axis mode for much of the time, but the five-axis functionality is there for when we need it, saving costs associated with workholding, handling and work-in-progress. At the same time, it helps with accuracy by being able to access parts with shorter tools and by cutting down on manual re-fixturing.”

He also appreciates the ergonomics of the V-30iT, pointing out that the rotary table when flat is at the same level as the fixed table, so there are no clearance issues. Control is provided by a Fanuc 0i-MF Plus, although Siemens, Fagor and Heidenhain are optional, as is the specification of 4+1 or full five-axis interpolation.
For further information www.wh-lead.co.uk