Precision is no ‘pipe dream’ for Pipetronics

As a manufacturer of high-performance electric and hydraulic sewer pipe rehabilitation robot systems, Pipetronics GmbH utilises two in-house CNC machining centres fitted with a wide range of Big Kaiser tools and tool holders that are available in the UK from Industrial Tooling Corporation (ITC). With headquarters in the South German town of Stutensee, Pipetronics uses the Big Kaiser range of products for the production of its robots’ turned and milled components.

To ensure complete coverage of all production processes, Pipetronics purchased a Grob G350 five-axis machining centre and a Mazak i400 ST turn-mill centre. Both feature robot automation.

“To mill very close to the clamping device along the spindle, a slim, stable and precise tool holder is required, which is where tool-holder specialist Big Kaiser comes into the picture,” says Rolf Dettinger, head of CNC manufacturing at Pipetronics. “From my previous job, I have significant experience with Big Kaiser spindle tools and Big Daishowa tool holders. After being repeatedly disappointed by the quality of the default chucks used on the Grob, I finally contacted Big Daishowa and they kindly provided us with the Mega Double Power Chuck for testing.”

Seeing the impressive results during the test phase, Dettinger was so impressed that he ordered several Micro collet chucks from the Mega Chuck series for the Mazak machine in addition to the tested power chuck.

“For our application, the Big Micro Chuck collet chucks offer optimal performance characteristics for machining hard-to-reach workpiece areas, where conventional collet systems fail to deliver,” he says. “Thanks to its groove-free collet nut, vibration at high speeds are prevented. The key is that this Big Kaiser micro-collet system is slim enough to implement in all our machining operations.”
For further information www.itc-ltd.co.uk

Subcontract manufacturing holds steady

In the face of rising energy prices, coupled with political and economic uncertainty, the latest Contract Manufacturing Index (CMI) reveals that the UK subcontract manufacturing market held steady in the third quarter of the year. The CMI for Q3 2022 was 102, compared with 101 in Q2 2022, an increase of 1%. Overall the market was marginally up on the average level of activity during 2021.

In Q3 2022, machining accounted for 39% of the total market with fabrication making up 54%. Other processes, such as moulding and assembly accounted for the remainder. Commenting on the figures, Karl Wigart, owner of CMI producer Qimtek, says: “Although the overall figures suggest that the market has steadied, there is still a lot of turbulence and uncertainty out there. September was slow across all categories and, while October is much better, we still have many buyers who are waiting for clarification.”
For further information www.qimtek.co.uk

Hainbuch expands quick change-over portfolio

To strengthen its position even further in the area of stationary systems, Hainbuch, a manufacturer of high-precision clamping devices, has acquired the Docklock zero-point clamping system from Vischer & Bolli AG in Switzerland.

The Docklock system has been on the market for more than 20 years, while its features and user benefits match perfectly with Hainbuch’s product philosophy. Hainbuch has been offering quick change-over systems or zero-point clamping systems for lathes for many years, and now it is expanding its capabilities in the area of stationary systems. The four variants of the Docklock system now have Hainbuch branding. Both pneumatic and hydraulic variants are available for either manual or automated change-over.

According to Hainbuch, the Docklock zero-point clamping system has two decisive advantages over other systems. The first is form-fit clamping with a collet or clamping segments, ensuring stiff clamping and higher repeatability. This also means that there are no pressure marks on the clamping bolt compared with systems featuring balls or slides, which lead to inaccuracies and consequently the need to replace the clamping bolts. Secondly, it is impervious to dirt and swarf, which means less wear and less maintenance. The base plate, which screws on to the machine table, provides the base for a quick change-over.

Notably, it is possible to change the clamping device combined with Docklock in just two minutes. The zero-point clamping system thus produces savings in terms of production time and cost. Using the interface, users can perform set-up outside the machine, thus avoiding lost production. The collet chuck lock ensures the trouble-free insertion and removal of workpiece pallets, while direct installation on machine tables, pallets or fixtures can be implemented cost-effectively by means of flanged cylinders.
For further information www.hainbuch.com

Automation investment proves its worth again

Mills CNC, the exclusive distributor of DN Solutions’ machine tools (formerly Doosan machine tools) in the UK and Ireland, has recently supplied an automated machining cell to a precision aerospace subcontract specialist. The cell was delivered and installed at ASG Arrowsmith’s machine shop facility in Coventry and is being used, at present, to machine a range of pre-production, high accuracy aero-engine parts for the new, ultra-efficient Rolls-Royce Pearl 700 business aviation engine.

Says Jason Aldridge, ASG Arrowsmith’s managing director: “We’re gearing up for full production and, since the cell’s installation, have been focused on designing, optimising and proving-out the machining processes for eight Pearl 700 engine parts ready for PPAP, a standardised aerospace industry process for the design and manufacture of new and revised parts.”

The parts being machined by ASG Arrowsmith are all made from aerospace-grade titanium alloys and other exotic materials. They are machined to exacting tolerances and super-fine surface finishes, and are characterised by their complexity and intricate features – many of which can only be produced economically by using simultaneous five-axis machining technology.

DN Solutions’ DVF 5000 machining centre provides ASG Arrowsmith with full five-axis simultaneous machining capabilities and, as such, enables the company to machine complex, high-precision parts to completion in a single set up. To improve productivity and process efficiencies the machine is integrated with a compact eight-station automatic workpiece pallet changer: each pallet is 350 x 350 mm in size and has a 250 kg maximum load.

ASG Arrowsmith regularly invests in advanced machine tools and automation systems from Mills CNC.

“We are advocates of the advanced technologies they supply and the applications and technical support they provide,” says Aldridge.
For further information www.millscnc.co.uk

Helping aerospace motor manufacturer take-off

As a company that specialises in providing electro-mechanical solutions to the aerospace and defence sectors, Rochdale-based NEMA Ltd is at the cutting edge of technology. To work at this end of the industry, the company invests in machine tools from the Engineering Technology Group (ETG). NEMA acquired its first ETG turning centres back in 2018 and this has been followed by 3D printing technology, a Mitsubishi EDM and most recently a Quaser MV184 CNC machining centre with a Nikken 4th axis rotary system.

The company’s managing director Andy Wilding says: “We’ve worked with ETG for several years and they always have the solution we require. The staff are friendly, supportive and always available, and we have a great relationship – but most importantly, the technology is fantastic.”

Alluding to why the 40-employee business required a new machining centre, Wilding continues: “We have a machining centre that is now approaching 20 years old and, while it still performs brilliantly, we want to reduce our reliance on an older machine that is susceptible to increased maintenance and downtime than a newer machine – especially as we win more new work. Additionally, a lot of our milling work revolves around the design, development and manufacture of electric motors for the next generation of ‘electrified’ aircraft. As the motor units evolve to generate more power, they subsequently increase in size, and our 400 x 800 mm bed on the existing machining centre was too small for many of the new parts coming through our door.

“The four-axis Quaser MV184 is not only faster, the build quality has created a more stable platform and this is giving us improved tool life, surface finishes and process reliability,” adds Wilding.
For further information www.engtechgroup.com