UK NEWS

Automation can be the key to success

The adoption of robotics and automation in UK manufacturing has the potential to improve productivity, efficiency and quality across multiple sectors, delegates discovered at a Manufacturing Technology Centre conference: ‘Robotics and Automation – A New Perspective’. According to speakers at the conference, the adoption of robotics and automation offers the potential to overcome problems such as labour shortages, skills shortages and low productivity.

More than 300 delegates from a wide range of industries shared insights into the transformational benefits of cutting-edge robotic technologies and heard how automation can improve productivity and drive global competitiveness for UK businesses. Topics covered at the conference included overcoming barriers to adoption and meeting the challenges presented by automation.
For further information www.the-mtc.org

HyperMILL revs-up productivity at Alcon Precision

As part of the Alcon Group, Alcon Precision Engineering has been at the cutting edge of performance automotive manufacturing since its inception. To manufacture complex components for the automotive and motorsport sectors, the company relies on HyperMILL CAM software from Open Mind Technologies.

Previously known as GE Precision before its acquisition by the Alcon Group, Alcon Precision Engineering has been using HyperMILL since 2008. When the Tamworth-based Alcon Group, a manufacturer of brakes and clutches, recognised the quality and surface finishes of the components manufactured at Alcon Precision Engineering, it also adopted HyperMILL CAM software to improve the quality of its components. For Alcon Precision Engineering, a company that has always had its niche in the high-end manufacture of motorsport engines, gearboxes and critical components, a high-end CAM system has always been of critical importance.

Alcon Precision Engineering’s managing director Garry Edwards says: “I’ve used all the leading CAM systems down the years and they all have their individual quirky features that make them a feasible choice, but HyperMILL has all the same features of all its rivals and lots more besides.”

He continues: “A major benefit that stands out is the tool paths within the surface machining modules. Parts like engine covers need to be aesthetically perfect and with HyperMILL, if the middle component has a distinct contour shape, we can select the contour as a guide for the tool path to replicate. This will ensure the entire tool path follows the contours of the part to blend perfectly the surface. Comparing this and other features, HyperMILL is a world apart from other CAM systems.”

Referring to other key features within HyperMILL, Edwards adds: “Another advantage is the feature recognition option, which creates less reliance on our team having to create geometries, surfaces and guide curves. The system is very efficient in terms of production engineering and programming times. Previously, we invested in a different CAM system that was very clunky, took a long time to process tool paths and offered no feature recognition, so we decided to change. Once I had a demonstration of the capabilities of HyperMILL, I was sold.”
For further information www.openmind-tech.com

Gestamp and In-Comm launch training centre

A major UK automotive supplier is joining forces with In-Comm Training to boost its learning and development offer and support employee retention. Gestamp, which manufactures components for use in car body structures, is investing in a dedicated training centre at its plant in Four Ashes, Wolverhampton. Six classrooms will deliver Lean Manufacturing Apprenticeships for a minimum of 60 existing team members every year, as well as a host of other development activities designed to increase the skills base of its 650-strong workforce. The Gestamp Training Centre will house two In-Comm Training experts.
For further information www.gestamp.com

Refurbished machines cost college around 50% less

Sorted Machine Sales recently sourced and refurbished four pre-owned Harrison M300 lathes for the Salisbury campus of Wiltshire College & University Centre. The investment will help the campus establish a new, fully equipped engineering department ready for its first influx of T-Level students and apprentices in September 2023.

“Due to the unfortunate closure of the local UTC, we’ve been investing heavily in an engineering department for Salisbury, which includes a machine shop,” explains Ben Elger, deputy head of department – engineering (automotive) at Wiltshire College & University Centre. “We inherited five lathes and five mills from the UTC and wanted a machine tool specialist to inspect them.”

Sorted Machine Sales is a long-standing partner of the established engineering department at the nearby Chippenham campus of Wiltshire College & University, so Elger reached out.

“Upon inspection, Sorted concluded that although the mills were good, the lathes were not fit for purpose,” he says. “They made some proposals and we opted for four reconditioned lathes. From our homework we saw the Harrison M300s as a good bridge between academia and industry, with a solid reputation for longevity.”

After sourcing the pre-owned lathes, Sorted Machine Sales set about bringing them up to scratch.

“We performed a comprehensive strip-down and refurbishment, replacing any worn parts as we went,” explains Marc Bowers, director at Sorted Machine Sales. “We added new coolant hoses, LED lights, safety guards, quick-change tool posts and a DRO. The machines also got a complete repaint. It was the right balance: sourcing decent pre-owned machines when the budget for new wasn’t available. We saved the college around 50% against the price of new machines. Furthermore, we delivered a complementary tooling package that included cutting tools, chucks, centres and tool holders.”

Concludes Elger: “Sorted were fantastic from the outset, providing us with solid options. Furthermore, the machines look immaculate; you wouldn’t think they were reconditioned. Sorted will now service and maintain the machines on our behalf.”
For further information www.sorted-uk.com

XYZ machines reduce cutting times for impellers

Sheffield-based Straaltechniek UK has been manufacturing equipment for the surface preparation industry since 1982 with its range of blasting and shot-peen machines.A key element of the blast wheel is the impeller, which is made from D2 tool steel. Originally manufactured in several operations on a lathe and then a machining centre, this component has six side apertures making it an ideal part for production on a turn-mill machine.

Ryan Doxey, machine shop supervisor, says: “We installed the XYZ TC 320 LTY in November 2022 as it has a full C axis and driven tools on a Y axis, so we can virtually finish one impeller from a solid billet in a single operation. Significant savings in handling, set-ups and faster machining combine to give us a valuable reduction in cycle times. There are a large number of different impellers as, we not only make blast wheels for our own machines, but also retrofit and refurbish machines from other manufacturers, bringing them up to the latest modern efficiency standards. We carry out all the programming on the shop floor and the Siemens 828D ShopTurn Touchscreen control is a favourite with our machinists.”

As well as the XYZ TC 320 LTY, the company also has a XYZ VL 425 lathe with ProtoTRAK control, which turns the blast wheel itself.

“The blast wheels can be up to 405 mm diameter, and we program them on the ProtoTRAK control on the shop floor with sufficient capacity to hold them in soft jaws to complete the machining,” explains Doxey.“The ease of programming on ProtoTRAK and the reliability of this machine gave us the confidence to invest in the XYZ TC 320 LTY and ShopTurn.”
For further information www.xyzmachinetools.com