SUBCONTRACTING NEWS

How to optimise base-plate removal from 3D-printed parts

Stirling-based CA Models, a specialist in high-quality, fast-turnaround metal and plastic additive manufacturing, is using new investment in two wire-erosion machines from Sodi-Tech EDM to optimise the process of removing 3D-printed parts from their build platforms.

“We had two Sodick wire EDM machines that were still running well but getting on in years,” explains founder and managing director Clark Campbell. “I felt it was the right time to bring in some new technology for the next decade. The new Sodick machines are even more accurate and faster. At CA Models we are in the ‘quick’ business, where just about every client wants their parts yesterday. That’s why we need an in-house resource when it comes to wire erosion. Every time we have a really complex, accurate part to produce, the clock is ticking.”

He adds: “I think Sodick technology is brilliant and the reliability of the machines warrants some loyalty in my opinion,” says Mr Campbell. “I went to an open day at Sodi-Tech EDM’s Warwick facility and was really impressed with the latest machines, which will play their part in a big way over the coming years.”

Installed in September 2022, the new Sodick ALC600G and ALC800G wire EDM machines are already busy.

“For example, take a titanium build platform with 14 motorsport parts on the base,” says Mr Campbell. “When the printing process is complete, the entire platform goes into our furnace for heat treatment for 24 hours, after which we wire-off all the components from base plate using our Sodick technology. As the wire cuts so finely we do not lose any dimensional accuracy in the parts. Furthermore, the machines wire so quickly that we get a head start in finishing the components.”
For further information www.sodi-techedm.co.uk

DMC achieves certifications

The Digital Manufacturing Centre (DMC) has received a key aerospace certification that demonstrates its commitment to production quality and traceability. Working alongside the Midlands Aerospace Alliance and the Manufacturing Technology Centre, the DMC has been awarded AS9100 Rev D and ISO 9001.It makes DMC one of the few commercial additive manufacturing businesses in the UK to receive AS9100. In meeting the requirements for this quality management system, the DMC has ensured that it is well-placed to meet the current and future needs of the aerospace industry.
For further information www.digitalmanufacturingcentre.com

PRODUCTIVITY AND EFFICIENCY GAINS AT THE DOUBLE

Mills CNC, the exclusive distributor of DN Solutions’ (formerly Doosan) and Zayer machine tools in the UK and Ireland, has recently supplied ABG Rubber & Plastics, a precision subcontract specialist and part of the Oadby group of companies, with two high-performance, multi-tasking lathes.The machines, both 10” chuck, FANUC-controlled Lynx 2600SY turning centres, are now in situ at ABG’s 20,000sq ft manufacturing facility in Northampton.

The new Lynx lathes which, incidentally, are the first DN Solutions’ (Doosan) machines to be acquired by ABG in its 48-year history, have significantly strengthened the company’s, already impressive CNC machining resources.

Since installation, the lathes, fitted with bar pullers to increase their productivity and facilitate a measure of automated operation, have been put through their paces machining a wide range of high-precision parts and components. ABG makes these bushes, bearings, shafts, wheels, rollers and camsfrom a wide range of engineering plastics that include PEEK, PVDF, nylon 6 andpolyethylene.

The parts, machined and supplied in medium to large volumes, are often characterised by their delicate and intricate features and tight geometric tolerances.They are machined for a diverse range of customers operating in, and serving, a multitude of industries that include automotive, medical, pharmaceutical, materials handling, construction, and food and beverage, to name but a few.

Despite their relatively recent installation (three months), the lathes have already made their mark helping to improve ABG’s productivity and process efficiencies.

Says Chris Woolley, ABG’s general manager:“Our Lynx lathes are powerful, accurate, flexible and reliable.They are equipped with a number of productivity-enhancing technology features that include a ±52.5 Y axis, a 6-inch chuck sub-spindle (4500rpm) and driven-tooling capability (5.5 kW/5000 rpm). These features enable us to machine complex, high-precision parts in one-hit.”

He adds: “This ability to reduce set-up and part cycle times, in particular, is helping us improve our process efficiencies and is already having a positive impact on customer lead times and the cost-per-part.”

ABG Rubber & Plastics, acquired by the Oadby group of companies in 1998, is a processor of engineering plastics and industrial rubber with a reputation based on quality, technical excellence and customer service. The company is ISO9001 and ISO14001 certificated, and is the CNC machining specialist within the Oadby Group.As such, the company has a well-resourced production facility which, combined with the considerable technical skill and experience of its staff, enables it to offer a complete one-stop shop, including design for manufacture (DfM) services, to customers: everything from prototypes through to large-volume batch production.

To maintain its leading position in the market, ABG is committed to continuous improvement and, as a consequence, regularly invests in its people, plant and equipment, as well as its processes and systems.

With business returning to pre-pandemic levels the company, back in early 2022, made the decision to further increase and improve the capacity and capabilities of its machining operations by investing in two new CNC lathes.

Says Anthony Morbey, ABG’s technical manager:“The pandemic did have an adverse effect on certain sectors that we serve, and this naturally caused a hiatus in our investment plans.Thankfully, this was short-lived and, with demand returning for our machining services, we moved quickly and decisively to upgrade and strengthen our CNC turning resource.”

Having previously invested in a lathe with driven-tooling capabilities, as well as in sliding-head technology and a number of five-axis machining centres, ABG did not need to be convinced about the productivity and performance benefits of multi-axis machine tools and the competitive edge they provide.

Continues Morbey:“After careful analysis of our machining operations we determined that we needed two new high-performance CNC lathes and, in order to meet our immediate and future turning requirements, both would need Y axes and sub-spindles.”

In addition to their multi-tasking capabilities, ABG also required the two new lathes to have a small footprint and be available relatively quickly after the time of order.

“Space is at a premium within our production facility, which is why both lathes needed to be compact in size and, because of the high demand for our turning services, we needed the new lathes to be delivered as soon as was practically possible,” explains Morbey.

Although ABG had not previously invested in DN Solutions’ or Doosan machine tool technology, the company placed an order for two Lynx 2600SY machines.

“We did our homework and researched the market by talking to a number of suppliers, customers and third parties”, explains Woolley.“It soon became apparent that DN Solutions’ machines have great reputation in the market for their performance and reliability, and that Mills CNC’s after-sales service and support [including its machine tool servicing and its wear and replacement part provision], as well as its progressive machine tool stocking policy are also highly regarded and well respected.”
He continues: “As a consequence, we approached Mills with our machining needs and requirements and, through working collaboratively with them, fine-tuned the details of the turning investment.”

According to Mills CNC, Lynx 2600SY lathes are the number one choice for small precision turned-part processing.The 10” chuck machines are compact, have a rigid design and build and feature a powerful, high-torque main spindle (18.5 kW/3500rpm), roller-type LM guideways and 30m/min rapids. In addition to their Y axes, sub-spindles and live tooling, Lynx 2600SY lathes also feature servo-driven, 12-station turrets and were supplied to ABG with the new Doosan FANUC iPlus control with 15” touchscreen iHMI.

Concludes Morbey:“The new Lynx lathes have been placed opposite to one another in our production facility and, since their installation, haven’t missed a beat.The decision to invest in two Y-axis, sub-spindle lathes has paid dividends. We’re able to machine high-precision, complex parts faster, better and more economically than previously, and are considering investing in more Lynx lathes in the near future.
For further information www.millscnc.co.uk

Jones-Nuttall on right track with ITC

When Warrington-based Jones Nuttall undertook a review of the overall service and support from its supply chain partners, cutting tool vendors were under the microscope. This forensic review based on a multitude of factors opened the door to UK cutting tool manufacturer, Industrial Tooling Corporation (ITC).

Located in the northwest, Jones Nuttall is a subcontract manufacturer with more than 60 employees to help it supply more than 30,000 different components to over 250 clients every year. This client list includes recognised names such as London Underground, Network Rail, Linde Group, ScotRail and Bombardier.

The machine shop is very versatile with over 12 CNC Hurco milling machines and eight CNC lathes, including models from Mazak.Producing everything from 1-offs and small batches up to runs of over 1000 from a diverse range of materials, the company utilises solid carbide and indexable tools for turning, milling, drilling and threading. When the company was witnessing indifferent service from its regular vendors, the company turned to ITC.

ITC technical sales engineer Chris Fairbrother says: “To emphasise the quality and productivity of ITC tools, we first manufactured special form tools for hydraulic components used in the fluid control industry. With supply chain issues from its previous vendor on special tools, we demonstrated our expertise by understanding the requirements of Jones Nuttall, providing technical support and then manufacturing special tools on short lead times. The tools performed exceptionally well, laying a foundation of trust and confidence in the ITC brand.”

With the relationship blossoming, Jones Nuttall incrementally introduced more ITC solid-carbide end mills to its shop floor with impressive results.

“The performance of ITC solid-carbide end mills immediately reduced tooling costs by more than 20% at Jones Nuttall,” says Fairbrother by way of example.
For further information www.itc-ltd.co.uk

Technical collaboration delivers productivity gains

With over 50 years of experience machining components for the aerospace, defence, medical, electronic and automotive industries; utilising everything from two-axis lathes through to multi-pallet five-axis machining centres axis, Aylesbury-based CNF Precision Engineering could be expected to have all the expertise it needed. However, when it won a significant order to machine exhaust collector manifolds for a motorsport customer, it found itself in need of additional support.

The issue faced by CNF was the complexity of the components, which came in six variants, along with the material, 304 stainless steel.

“When we were faced with stainless steel that required extra-long tool overhangs, we knew we would need additional technical input,” says Mark Baron, CNF’sproduction manager.

Ceratizit provided a range of tooling on trial, with no commitment until successful completion of the process. Key to that success wasthe use of35 mm diameter (with 4xD flute length) KUB Pentron indexable insert drillsfor the main internal port machining, along with a selection of high-feed indexable insert milling cutters using button and square inserts, with finish milling completed using Ceratizit’s Silverline solid-carbide mills and Torus cutters.

The collaboration resulted in significant cycle time savings along with greatly improved tool life. For example, the indexable milling inserts are showing a 300% increase in tool life after testing a variety of carbide grades, eventually settling on Ceratizit’s grade for heat-resistant materials, CTCS245. A 20/30% gain in tool life was seen when switching to Silverline cutters for finish milling, when compared with an incumbent competitor cutter.

In terms of cycle time, the work undertaken with the Ceratizit Torus cutters proved to be productive, with 40-50% decrease in cycle time generated from the switch from a conventional ball-nose cutter to a Ceratizit Torus Monstermill cutter.Tool life also doubled.
For further information www.ceratizit.com