SUBCONTRACTING NEWS

Citizen machine helps TAS rebalance business

Around 20 years ago, Gareth Davies started Burton-on-Trent company TAS Engineering as a steel, stainless steel and aluminium fabrication shop.In 2014, he established a machine shop to add extra value to the products the company was forming and welding. Today, there is a pair of three-axis vertical machining centres on-site and a trio CNC lathes, the latest of which is a pre-owned Cincom L20 sliding-head turning centre from Citizen Machinery.

What prompted the purchase in October 2023 of this 20-year-old lathe, the company’s first sliding-head model, was a desire for more efficient turningof components in various materials from bar up to 20 mm in diameter. A case in point is the ongoing production of a 16 mm diameter, 316 stainless steel magnet holder, which is welded to a small, laser-cut and bent plate to form part of a safety unit for industrial switchgear. The turned component, of which 200 are required per month, was previously produced complete on one of two fixed-head, twin-spindle lathesin a 2.5-minute cycle.

It was apparent that the steel magnet holder could be produced more quickly on a modern Citizen L20 twin-spindle sliding-head turning centre due to the faster axis motions of the gang tool carriers on the former compared with the turret movements of fixed-head lathes. However, Davies was surprised to find it was possible to machine the part more than three times faster on the Cincom: the cycle now takes just 48 seconds.

He says that although the purchase price of the lathe was only about 24% of the investment needed for a modern 20 mm capacity L-series Cincom, he was treated by all Citizen Machinery UK staff as though he were purchasing a new L20.

For further information www.citizenmachinery.co.uk

Numachine makes gains with Hyundai-Wia VTL

Numachine, a thriving Hereford-based business specialising in CNC machining and subcontract manufacturing, is embracing the advantages of its new Hyundai-Wia LV800RM vertical turning lathe (VTL) supplied by TW Ward CNC Machinery Ltd (Ward CNC). The quality and performance of the machine are contributing to the optimisation of the company’s manufacturing processes.

Renowned for its robust and heavy-duty cutting platform, the Hyundai-Wia LV800RM VTL boasts a one-piece, square-type column and a stable shaft structure. Noteworthy features of the machine include a two-step chuck pressure mechanism designed to minimise workpiece deformation and ensure optimal chip evacuation. Within the LV series, a dedicated protection device prevents chips and other foreign materials from entering the main spindle.

The Hyundai-Wia LV800RM offers a maximum turning diameter and turning length of 800mm, coupled with a maximum spindle speed of 2000 rpm. This addition to Numachine’s workshop enhances its machining capabilities, reinforcing its commitment to precision and efficiency in manufacturing processes.

Speaking on the experience of working with Ward CNC, managing director Brandon Davies says: “It was an entirely smooth experience. Ward CNC took care of processes such as specifying the machine based on our application, placing the order, delivery, installation and operator training.”

He continues:“We’re pleased with the quality and performance of the Hyundai-Wia vertical lathe; it’s a good addition to our range of machines. There was only one small issue a few months ago which was solved rapidly by Ward CNC and we’re completely satisfied with the performance of the company’s service.”

Davies concludes: “Looking ahead, we plan to enter the bespoke motorbike and mountain bike manufacturing segment, with Ward CNC likely to play a crucial role in these projects.”

For further information www.wardcnc.com

Bharat Forge Daun relies on Emag machines

Unusually sophisticated components and high-strength materials for high-tech applications, like stator housings for electromobility with tolerances in micron range, are among the machining challenges tackled by the specialists at Bharat Forge Daun in Germany. At the centre of this activity areseveral vertical turning lathes (VTLs) from Emag, which operate around the clock, five days a week.

The vertical design of thesemachines played an important role in the investment decision, asa horizontal machine from another manufacturer had caused difficulties in the past. Annoying chip clusters would form, requiring manual removal two or three times a shift.

“It was therefore obvious to us that we should carry out these processes in machines with a vertical design, because their unhindered chip flow prevents disruptions,” explainsChristoph Steffens, head of mechanical engineering at Bharat Forge Daun. “Our objective was to achieve maximum process reliability.”

Another factor in the decision in favour of Emag was existing knowledge: the machine tool manufacturer used examples from other customers toshow how its machines optimise stator machining – with low non-productive times and high-precision handling processes. Integrated automation, including a pick-up spindle and lateral conveyor belt, ensures fast processes, while the stable base body is made of Mineralit polymer concrete.

Last but not least, the response time and the expertise of Emag’s service department play an important role for Bharat Forge Daun. A regional service technician is always on site within a few hours and solves any problems directly.

“So far we have always been helped with minor faults in record time,” says Steffens.

For further information www.emag.com

Leadership transition at Dean Group

Manchester-based casting specialist Dean Group is implementing an important strategic shift as part of its leadership succession plan. Effective 1 July 2024, Pulkit Ahuja will take up the role of managing director, succeeding the retiring Graham Stubbs. Pulkit, a key member of the Dean Group team since 2019, has been selected for his proven proficiency in directing the company’s commercial operations, contributing significantly to its enhanced positioning within the casting industry. This planned succession reflects the company’s commitment to a seamless transition in leadership that ensures continuity.

For further information www.deangroup-int.co.uk

Automatic loading and blasting without ‘teaching’

When Ottostahl GmbH had to replace an old rotary table shot-blast machine, the company insisted on short cycle times, high energy efficiency and relieving its personnel from strenuous and monotonous physical activities. Rösler and automation specialist Teqram met these challenging demands with the universally deployable Easy Shotblaster RDT 150 rotary table, equipped with a stationary ‘intelligent’ robot. This robot places workpieces on the rotary table in a manner that optimally utilises the entire table area without requiring any ‘teaching’ operations.


Ottostahl in Magdeburg produces up to 30 mm thick, highly precise plasma-cut and up to 300 mm thick flame-cut components. In its shot-blasting department the company is
utilising three machines (two continuous flow roller conveyor machines with an operating width of 3800 mm and a rotary table blast machine). After more than 60 years of use, the company is replacing its old rotary table blast machine with an RDT 150 system from Rösler.

The entire blast system integrates within a manufacturing cell measuring 8 x 8 m, consisting of an intelligent stationary robot and the RDT 150 shot-blast machine.

With its image processing technology, the vision-controlled robot automatically recognises components placed into its working section, completely independent from their position on the pallet. This capability eliminates the normally required time-consuming teaching or programming of the robot. Moreover, with the intuitive interface, no special knowledge is necessary.
After the automatic selection of a suitable gripper from the magazine, the robot picks up components and places them on the rotary table in the optimal position. It provides component data to the machine controls for selecting a suitable processing program. Halfway through the cycle, the robot automatically turns the components to blast the other side. The robot then returns finished workpieces to the pallet.

For further information www.rosler.com