MTD Audiobook

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Microloc transforms Scottish engineering operations 09/10/2025

Microloc transforms Scottish engineering operations Situated near Alva in Central Scotland, Qualtek Engineering serves everything from small customers to large international corporations with CNC machining services. Alongside its main manufacturing activities, Qualtek operates Bespoke Engineering, a specialist automotive division concentrating on restoration, classic cars, performance vehicles, and motorcycles. It is here that Microloc clamping technology is used. The nature of Qualtek’s work demands versatility that traditional workholding solutions struggle to provide. Ewan Montgomery, who oversees operations, explains: “It’s a very individual workshop with diverse needs. We specialise in restoration, classic cars, performance cars, and motorcycles, which means we’re constantly dealing with different projects needing different tooling approaches.” This diversity extends to tooling manufacture. “A good example is working on a classic car cylinder head with modern machinery,” Montgomery notes. “Buying old-fashioned face cutters commercially is hard to get and hugely expensive for standards that we don’t really need. Manufacturing our tooling became a cost-effective solution.” To accommodate substantial automotive components, Qualtek invested in a HAAS VF4SS machining centre. “The machine size is really to accommodate the size of materials that we’re working with—engine blocks, cylinder heads, etc. You need a certain size of footprint; otherwise, if they don’t fit, you can’t work,” Montgomery explains. Discovery of the Microloc Solution The introduction of Microloc workholding proved transformational. “Microloc was completely the solution that we didn’t know we were looking for,” Montgomery admits. “Very soon after I bought the machine, I’m buying a Microloc system, and it’s really one of the best things we’ve ever done.” Technical Advantages The Microloc system achieves exceptional accuracy through its integer location methodology, where components are clamped against fixed jaws, providing precise location in X, Y, and Z axes. The system maintains repeatability accuracy of ±25 microns, achieved through case-hardened jaws ground to ±10 microns relative to tenon keys. “The system is designed for machinists, and it’s designed to minimise setup time and provide micron-level accuracy,” Montgomery explains. “There’s nothing else out there that delivers this kind of modular setup that Microloc provides.” The precision aspect is crucial for automotive restoration work. “The accuracy, as we understand from manufacturing our own tooling, just a few microns out is enough to scrap a part,” Montgomery emphasises. One significant advantage is eliminating traditional setup procedures. “Traditional clamp vices have to be set up, have to be clocked in if you’ve got multiple operations,” Montgomery notes. “Things can move because it’s friction clamping, not keyed clamping, and you’ve got lots of variables, including temperature, user, and everything else that can go wrong.” Modular Flexibility The modular design allows clamping elements to be rotated through 90 or 180 degrees, enabling four-edge clamping configurations. Individual clamping modules deliver exceptional holding power. “The clamping force on these is unbelievable. I think we’re approaching a ton of pressure,” Montgomery reports. “You can place them anywhere on your table within 3mm of movement.” “It doesn’t matter if it’s a metre-long part or if it’s a 100mm long part, you’ll find a clamping place that will accommodate that width or length,” Montgomery explains. “You can have as many of these Microloc clamps as you wish on the table. You can have nested systems for repetitive work.” System Configuration and Fourth Axis Integration The Microloc baseplate mounts using bore tenon adaptors that locate into precision 16mm bores. The baseplate features precisely spaced, conical zero-point locations that accept tenon keys of various workholding elements. Integration of fourth-axis capability opened up new possibilities for complex automotive components requiring specific angles. “A lot of the machining originally was done off-centre,” Montgomery explains. “This particular manifold is at 45 degrees and using the fourth axis and the HAAS VF4SS machine accuracy, we can get that exactly to 45 degrees straight away.” Customisation and Service Support Rather than a standardised package, Microloc provided a tailored solution. “It’s a custom solution to suit a customer’s needs. It’s not a defined package. It can be made larger, smaller, wider, whatever, just depending on customer demand,” Montgomery notes. Service support extended beyond supplying the system. “Microloc provided tenons to fit our vices to make them quick release as well, so that we don’t really have any setup time now,” Montgomery explains. “When we have no clocking-in required, just simply mount them on X or Y-axis, and if that’s what you need, it will be instantaneous. It’s a five-minute job, and you’re ready to go.” Operational Efficiency and Quality Improvements Time savings achieved through the Microloc system have directly impacted operational efficiency. “The old way of doing it would be to set up a manual table, an indexing table, and you would be there for a very long time trying to get that right. Obviously, time is money,” Montgomery reflects. Perhaps most revealing has been the insight into historical manufacturing standards. “The conventional machining on older engines from around the world was not accurate, to say the least,” Montgomery observes. “When you are doing things like cylinder boring with a machine that can measure so accurately, you understand that the tolerances that things were made to were quite poor. We can make them better now than they were when they came out of the factory.” For Qualtek Engineering, adopting Microloc workholding has represented a fundamental shift in operational capability. The combination of precision, flexibility, and efficiency has enabled the company to tackle increasingly complex projects whilst reducing setup times and improving accuracy. In an industry where precision measured in microns can determine success or failure, the Microloc system has provided the foundation for sustained growth and enhanced capabilities in both general manufacturing and specialist automotive restoration work. /episode/index/show/mtdmag/id/38155270

Hirschvogel revs-up optimisation with Vericut 09/10/2025

Hirschvogel revs-up optimisation with Vericut As an automotive supplier manufacturing up to 20,000 parts per day, the Hirschvogel Group operates at the pinnacle of automated series production where optimised cycle times are essential. By using Vericut simulation and optimisation software, machining processes can be analysed and optimised for series production in advance. From Village Forge to Global Manufacturing Leader Founded in 1938 as a village blacksmith in Denklingen, the Hirschvogel Group has grown into a global leader in producing and refining highly formed steel and aluminium components for the automotive sector. With around 6,000 staff across nine plants worldwide, generating €1.21bn in revenue and producing 342,000 tonnes of steel and aluminium annually, the company supplies well-known car manufacturers with technically advanced, ready-to-install components. Today, Hirschvogel ranks among the world’s largest automotive suppliers in hot and cold forging of steel and aluminium, plus subsequent machining. Its customers include all major automotive manufacturers and suppliers worldwide, with the company producing components and assemblies for drivetrains, transmissions, chassis, bodywork, fuel systems, combustion engines and electric motors. Development Partner and Manufacturing Specialist A clear trend shapes modern automotive manufacturing: “The components we develop are constantly becoming lighter whilst also needing to withstand high loads,” explains Peter Zotz, responsible for machining process development at Hirschvogel’s Schongau plant. Hirschvogel brings extensive experience and innovation to highly stressed, weight-optimised parts and components. From forged parts to ready-to-install components, the family-owned Bavarian company provides everything from a single source. “We are a development partner and manufacturing specialist for the automotive industry. Besides forging, machining plays a major role in production,” says Zotz. As a cost-sensitive supplier dealing with high volumes, every penny and second counts. “That’s why we’ve been using Vericut since 2013. It allows us to identify errors and optimise our manufacturing processes before actual machining even begins.” Zotz emphasises the critical importance of advanced optimisation: “Thanks to the process reliability gained through Vericut, we are able to optimise the machining of formed steel and aluminium components.” Vericut as a Key Component of the Process At Hirschvogel, all machining programmes are written manually as NC code using an editor. “This is the fastest process for our needs,” says Philipp Berchtold, responsible for programming at the Schongau site, explaining this unconventional approach. As components become lighter, more complex and must be delivered ready for installation, machining challenges increase. To verify and optimise these programmes, Hirschvogel relies on Vericut. Because each part is optimised as much as possible, Hirschvogel uses a wide range of control types and machine tools. “Vericut is completely independent of control systems, and we can test and optimise our parameterised programmes at our desks before a single chip is cut,” Berchtold explains. For him, “The simulation and optimisation software Vericut is a firmly established and indispensable part of our process workflow.” “For the user, it’s the safest way to simulate real machining using a virtual machine,” adds Dirk Weiß, responsible for sales in Germany and Austria at Vericut. Hirschvogel’s product development process divides into distinct phases. In the quotation phase, space analysis of the production system takes focus. “Here, critical tools, clamping devices, loading/unloading and turret swing-outs are checked,” explains Berchtold. Once the system concept is finalised, the process development phase begins. “Each machine or control uses its own defined programme structures consisting of up to 150 subprogrammes,” says Berchtold, illustrating the complexity. Depending on the situation, existing programme structures may be reused or must be newly created or adapted. In the third phase, the component’s suitability for series production is reviewed by the responsible department and in-house automation technicians. After final approval, Vericut performs collision checks and process optimisation. “We focus on smooth production flow with no downtime to avoid any delays during actual machining,” Berchtold explains, adding: “And all of this happens before the part even reaches the machine.” The simulation takes only a few minutes. “If an error is found, you can fix it and continue simulating from that point,” adds Weiß. Comprehensive Data Package for Production The programming department at Hirschvogel creates a comprehensive data package for each part for series production use. It includes the programme structure, the programmes themselves, a reviewer file for feedback from production colleagues, and a machine setup sheet. “This data package speeds up setup and programme adjustments, which leads to significant cost savings,” says Berchtold, pleased with the results. This systematic approach ensures seamless transition from development to production, minimising potential errors and maximising efficiency throughout the manufacturing process. Further Optimisation with Advanced Capabilities Thanks to the process reliability provided by Vericut, Hirschvogel optimises machining of forged steel and aluminium parts for the automotive industry before production begins. “We are currently testing additional feed rate optimisations using the Vericut Force module, which we expect will yield another productivity boost,” says Berchtold. Force is a physics-based optimisation method that determines the maximum safe feed rate for given cutting conditions based on cutting force, spindle power and maximum chip thickness. Weiß reinforces the importance of this capability: “In series production, every second counts—manufacturing processes must be optimised and machining operations pushed to their limits. With Vericut and the Vericut module Force™, we offer highly cost-effective support in this area.” Together with Vericut, Hirschvogel is also working on achieving even more detailed cycle time analyses. “We aim to reduce theoretical cycle time deviation to under one per cent,” concludes Weiß, highlighting the precision and reliability that makes Vericut an indispensable tool for modern automotive manufacturing. /episode/index/show/mtdmag/id/38155255

Transforming production capabilities with Hanwha 09/10/2025

Transforming production capabilities with Hanwha Machined Component Systems (MCS) PLC stands as a centre of manufacturing excellence in the heart of the Midlands, operating from its facility in Redditch. This innovative and progressive subcontract-machining specialist has built a reputation for delivering precision-engineered machined components to diverse industry sectors, including automotive, petrochemical, environmental, transport technologies, marine, healthcare technologies, and white goods. Founded by Warren Gray’s father, MCS has been under Warren’s leadership for the past decade. During that time, the company has transformed from a traditional engineering firm into a sophisticated manufacturing hub. This has been possible with investment in cutting-edge technology that includes three Hanwha sliding head turning centres from Dugard. Enforcing the message of what sets Worcestershire-based MCS apart is Warren’s unwavering investment philosophy. “We’re very proud of the people that we employ. Without the people and the investment that we’ve made in the machine tools, you are nothing. It is what takes the company forward, and we’ve just invested in CAD/CAM software to parachute the company forward, and we’re training four people on that at the moment.” Warren Gray’s approach to automation demonstrates a deep understanding of manufacturing progression that has followed a journey from manual to automated operations. “Sliding head turning centres use barfeeds for automation anyway, but when you are making larger components on fixed head lathes, you may have started by opening and closing the door and actually having the billet in your hand with a person and hand feeding the machine. We’ve actually taken that away from the person by investing in collaborative robots, industrial robots, and then moving it even further, you then go on to machine tools with it, with its own pallet pool to increase the automation.” Opting for Dugard… By 2022, MCS faced a critical decision regarding their sliding head capability. “We’d had some very good sliding head machines from another manufacturer over a number of years. Those machines were beginning to age, and we went out to three or four sliding head manufacturers, and we went to each of them with the same suite of parts, asked them to tender and provide a complete turnkey proposal for those parts, and Dugard won.” The selection process wasn’t simply about specifications or price comparisons. Warren insisted on a comprehensive evaluation that would reveal real-world capabilities. “Dugard invited us down to Brighton. I took my lead setter and a senior sliding head machine setter as well. The three of us went down to Brighton. We spent the whole day reviewing Dugard as a company, and also looking at the Hanwha machines in action, and on the back of the quotation they put together, they won our business.” This hands-on approach reflects Warren’s belief in involving his team in critical decisions. By bringing his lead setter and senior sliding head machine setter to Brighton, he ensured that the people who would work with these machines daily had input into the selection process. What distinguished Dugard in Warren’s evaluation was their complete approach to customer service and a level of support infrastructure that clearly resonated with Warren’s emphasis on reliability and long-term partnerships. The company now has three Hanwha machines, the XD20II-V NHY, the XD26II-V NHY and the XD38II-R NHY. The 6-axis turning centres have a diameter capacity from 20 to 38mm with an ability to turn parts up to 545mm long. The Hanwha sliding head range features a comprehensive lineup ranging from 3 to 42mm diameter capacity, powerful high-end CNC units, comprehensive tooling platens and configurations, and what stands out against competitor machines is the high-rigidity machine structure. This construction philosophy sees Hanwha make the machines 20 to 30% heavier than competitors’ machines of similar capacity. This additional mass translates into performance benefits, with customers reporting massive improvements in heavy cutting capabilities, tool life, and reduced cycle times. The proof of any investment lies in its real-world performance, and Warren’s assessment of the Hanwha implementation is unequivocally positive. “The Hanwha machines have come into this business, and they are very, very good machine tools, and we are very happy,” he states with evident satisfaction. “We serve a vast array of different industry sectors, and the Hanwha’s serve all those industry sectors which are automotive, environmental, medical and domestic gas. So, these machine tools could be making any industry components at any time,” Warren explains, highlighting the versatility that makes this investment so valuable to MCS’s diverse customer base. The phased implementation approach that Warren adopted allowed MCS to validate performance, optimise integration, train personnel, and prove return on investment before committing to additional machines. This methodical approach reflects his broader management philosophy of making informed decisions based on evidence rather than speculation. Warren’s philosophy on quality is deeply embedded in the company culture. “Quality is not an option,” he states. This commitment to measurement excellence is complemented by the precision capabilities of the Hanwha turning centres, creating a complete quality ecosystem that ensures consistent, repeatable results across all production runs. The collaboration between MCS, Dugard, and Hanwha represents more than a simple supplier-customer relationship; it exemplifies how strategic partnerships can drive manufacturing excellence when built on shared values of quality, reliability, and customer service. Warren Gray’s methodical approach to vendor selection, combined with Dugard’s comprehensive customer service and Hanwha’s innovative technology, has created a synergy that benefits all parties. Warren’s assessment of the partnership remains overwhelmingly positive: “The Hanwha machines are very, very good machine tools, and we are very happy.” This success stems not just from the technical capabilities of the machines but from the alignment of values between MCS and Dugard. /episode/index/show/mtdmag/id/38155165

Taking tradition to high-tech precision 09/10/2025

Taking tradition to high-tech precision Established in 1967 by Reginald Newnham and now under third-generation family leadership, Newnham Engineering Limited has undergone a remarkable transformation from traditional machining to cutting-edge 5-axis manufacturing. Through investments in DMG MORI machine tools, this West Sussex-based company has acquired a DMU 75 monoBLOCK, DMU 100 FD duoBLOCK, and a CMX 70 U. Operating from their modern facility on Lancing Business Park, Newnham serves demanding sectors including oil and gas, surveillance, F1, and specialised industrial applications. What distinguishes them in today’s competitive landscape is their commitment to ‘machining excellence’, backed by technology investments that have fundamentally reshaped their capabilities and market positioning. The Technology Foundation The DMU 75 monoBLOCK serves as the cornerstone of Newnham’s 5-axis capabilities. This machine handles workpieces up to 840mm in diameter, 500mm in height, and 600kg. Its 20,000rpm spindle capability and monoBLOCK construction provide the precision and versatility essential for complex aluminium components that dominate Newnham’s production. “It was quite a smooth transition into our latest 5-axis machine, the Monoblock 75,” Lawrence Newnham explains. “Like all the pain we come through with learning how to use the new CAM system, how to use full 5-axis, how to use zero pointing, and using all of that efficiently as well. Going onto the Monoblock 75 it was so smooth.” The DMU 100 FD duoBLOCK is capacity expansion with the ability to handle workpieces weighing up to 2,200kg. This 4th generation duoBLOCK machine delivers 30% more precision, performance and efficiency compared to previous generations through FEM-optimised structure and enhanced components. The dramatic capabilities become evident when Lawrence describes processing large aluminium billets: “Currently, the part on the machine is one ton. We’ll shy of that, and it finishes up about 250kg. So, a 75% material reduction there. We can fill a bin up in probably 45 minutes – that’s how quickly we can remove material.” Completing the trio, the CMX 70 U brings 5-axis precision to smaller applications with its C-frame design and mineral cast bed construction. The machine features 750 by 600 by 520mm travels, handles components up to 350kg, and operates with a 12,000rpm spindle delivering 13kW power and 83Nm torque. Business Transformation Through Strategic Partnership Newnham’s evolution illustrates the challenge many manufacturers face transitioning from indexed 5-axis machining (3+2) to full simultaneous 5-axis operations. “We started with three plus two, and then we took this big jump to a DMG MORI DMU 100 FD duoBLOCK, it’s a hell of a machine,” Lawrence noted. This technological leap required significant investment in CAM programming expertise, and setup procedures. However, the learning curve ultimately positioned Newnham with capabilities that differentiate it from competitors. Phil Newnham reflected on the transformation: “The components we do these days are night and day in technology compared with what we used to do. It’s just really exciting.” The partnership with DMG MORI extends beyond equipment supply to comprehensive support. Philip Clapp from DMG MORI described the collaborative approach: “Lawrence and Phil turned to me one day and said, ‘can you come and see us?’ We’ve got an absolutely great job, a big part, and we want your help and your partnership to develop the process and make sure we get the right machine for this customer.” This partnership model encompasses application engineering to match machine specifications with customer requirements, process development for optimising cutting parameters and tooling strategies, comprehensive training ensuring operators maximise machine capabilities, and technology road mapping for future investments aligned with market evolution. The DMG MORI investments have fundamentally expanded Newnham’s addressable market and strengthened customer relationships. Perhaps most significantly, the technology has enabled them to solve previously intractable manufacturing challenges. “We’ve got this customer up the road to us that has had these large components made throughout the world, and they’ve never been made right,” Lawrence explained. “So, we ended up getting this DMG MORI machine, and now we have the capability to make the parts, and to make them correctly to the customer specification.” The company now confidently supplies oil and gas applications requiring complex valve bodies and pressure vessel components with tight tolerances, surveillance systems needing precision housings and mounting systems, Formula 1 projects where lightweight aluminium components must meet exacting standards, and specialised industrial equipment including high-precision parts for milking machines. Technical Excellence and Advanced Features The three machines provide comprehensive capabilities through advanced technical features such as high-pressure cooling systems that are crucial for machining aluminium components, improving chip evacuation, extending tool life, and maintaining dimensional accuracy during extended cycles. The larger machines utilise HSK 100 tooling systems, providing superior rigidity and repeatability compared to traditional tapered spindles. A Model for Manufacturing Evolution Newnham Engineering’s transformation demonstrates how manufacturers can navigate the transition to advanced manufacturing through strategic technology. The partnership between Newnham and DMG MORI illustrates that success in today’s competitive manufacturing environment requires more than advanced equipment. From a family business founded to a technology-enabled precision manufacturer serving Formula 1 and other demanding industries, Newnham’s journey provides a roadmap for manufacturers seeking to advance their capabilities in an increasingly competitive global marketplace. /episode/index/show/mtdmag/id/38155155

Stator machining solution ready for series production 09/10/2025

Stator machining solution ready for series production A process for complete machining of stator housings for electric motors, developed by Chemnitz machinery manufacturer NILES-SIMMONS and tool manufacturer MAPAL, has reached series production. Suppliers and OEMs now use it to produce components for drives in battery-powered electric vehicles and hybrid models. Both manufacturers recently proved in a development project that highly cost-efficient and precise production of stator housings is possible on a pick-up lathe. The parts feature external ribs for cooling circuits and are installed in the larger motor housing. Whilst NILES-SIMMONS used a converted modular lathe during development, a machine specifically designed for stator production has now entered the market. The basis for development was the vertical machining centre from the RASOMA brand, which, like NILES-SIMMONS, is an NSH Group brand. The RASOMA DZS 400-2 indicates operation with two workpiece spindles. For series production, the machine features side-mounted pickup and drop-down areas for finished parts. Components are supplied and removed via conveyor belts. With manual assembly, 10 to 20 components can be buffered through automation, allowing multiple systems to operate simultaneously while workers attend to other processes. “We’ve realised highly simple automation as standard. No robots or blocks on the machine are required.Operators can place parts directly on the pallet belt,” explains Thomas Lötzsch, Sales Manager at NSH TECHNOLOGY. The machine integrates easily into existing production environments, with compact installation dimensions of 7.50 by 2.60m. The RASOMA DZS 400-2 design was developed in collaboration with LTH Castings, a partner with extensive casting experience and expertise in machining complex, high-quality, thin-walled pressure die-cast aluminium components. The design, therefore, directly incorporates practical experience and user requirements. Complete machining in two clamping systems Finishing occurs on the vertical machine in two clamping systems. A clamping device picks up the workpiece from above and moves it to various machining stations. At a re-clamping station, the part is rotated 180 degrees and picked up by the second workpiece spindle for finishing. During second clamping, machining of the next component begins simultaneously at the first pick-up. The process begins with pre-roughing the component’s various inner diameters. The tool remains stationary whilst the workpiece rotates. “Unlike conventional turning with a blade, machining with a four-blade ISO boring tool on an HSK-A 100 spindle takes just a quarter of the productive time,” says MAPAL regional sales manager André Ranke. The inner tool also rotates. Tool speed and workpiece speed differences produce cutting speed at the inner blades. The bell-shaped outer tool remains stationary. The component is placed in the gap between inner and outer tools for machining. This patented process reduces forces on the clamping system, avoiding the need for complex workpiece clamping devices with vibration-damping for precise machining of thin-walled components. “When designing the tool, particular attention was paid to the large chip volume and significant forces generated, as simultaneous inner and outer diameter machining is unusual,” explains Michael Kucher, Component Manager E-Mobility at MAPAL. During finishing, only the fine boring tool is driven whilst the component remains stationary. This prevents non-rotationally symmetrical workpiece shapes from causing material imbalances with negative impacts. The workpiece is then re-clamped and the outer area previously clamped in the flange area is machined. The re-clamping station can also relax the material before fine boring. The machine has two tool revolvers for driven tools carrying out further machining based on component requirements. Faster and more stable than expected “The RASOMA DZS 400-2 combines turning speed for pre-machining inner and outer contours with fine boring accuracy for finishing inner contours,” says Daniel Pilz, Project Leader at NSH TECHNOLOGY. With machine, tool technology, and process serialisation, positive prototype results were improved further. Process reliability exceeded expectations, allowing the targeted cutting speed of 700 m/min to be increased. “For aluminium machining, NILES-SIMMONS’ experience positively impacts tool technology and machine reliability,” explains Michael Kucher. The RASOMA DZS 400-2 achieves much shorter chip-to-chip time than milling centres because all tools are already in the working area. This reduces non-productive time. Using this technology, studies anticipated 50% cycle time reduction. Parts were initially measured, current guidance recommends testing one part per shift. Daniel Pilz uses figures to demonstrate this is more than adequate: “The RASOMA DZS 400-2 with special MAPAL tools achieves a process capability index over 1.67 for critical characteristics such as cylinder shape, diameter, and concentricity, meeting industrial specifications.” Customers already using the machine achieve annual outputs of up to 180,000 components in a three-shift operation. Success at high volumes LTH Castings in Slovenia is among the first to adopt the serial process for stator production on the RASOMA DZS 400-2. The traditional casting company has over 100 casting cells and processes raw parts on more than 250 CNC machining centres. Around 3,800 employees work across six sites. Dr Primož Ogrinec, CTO of LTH Castings, says: “With our all-in-one solutions from design to series production, we’re a key strategic partner for the automotive industry. Our range includes components for drives, motors for battery-powered electric and hybrid vehicles, steering and braking systems.” Robots load and unload the RASOMA DZS 400-2 machines in ultra-modern production. Like most automotive suppliers, LTH Castings produces components for various vehicle models. The RASOMA DZS 400-2’s flexibility, which only requires retooling of the clamping device and tool, makes it suitable for stator housing production. “With a single system using the new process, an optimal solution, tailored to manufacturer-specific needs in both quantity and quality, was developed and brought to series production maturity,” says André Ranke. Stator housing production can be carried out for diameters up to 500mm and components up to 500mm in length. “Every housing type we’ve seen can be manufactured on the RASOMA DZS 400-2—and we’ve seen plenty,” says Thomas Lötzsch. The project team was surprised when a major car manufacturer’s housing design required an internal component indentation. The sample component from MAPAL, specially designed for the process, didn’t present this challenge. Yet MAPAL quickly had a joint solution ready with NSH Group specialists: instead of the tried-and-tested fine boring tool, an ultra-precise actuating tool with four slides from MAPAL’s product portfolio created the desired inner contour. Machine-side, a connection designed in coordination with MAPAL was ready within days and achieved series production maturity during the ongoing order. With tightly networked development structures, both companies react quickly to newly developed contours. New benchmark for low costs per part The RASOMA DZS 400-2 with MAPAL tool technology has become established in series production, addressing quality issues seen on traditional turning and milling machines. Thomas Lötzsch describes cases where required shape and position tolerances were not met with reliable processes, resulting in up to 50% scrap. When quality was sufficient, cycle times were inefficient, leading to higher workpiece costs. A proven manufacturing process was missing. As price competition is tough among automotive suppliers, RASOMA DZS 400-2 development focused on minimising unit costs from the outset. This goal was achieved through high machine availability, short cycle times, machined component quality, and production with reliable processes. /episode/index/show/mtdmag/id/38155135

Serving success on a pallet 09/10/2025

Serving success on a pallet Servicing manufacturers in the medical, oil and gas, aerospace, automotive, MOD, and F1 sectors, Rushden-based R&G Precision Engineering Ltd prides itself on the level of service it delivers to its customers. To meet its clients’ tight deadlines and quality demands, the company founded 50 years ago has invested in a series of multi-pallet machining centres from Matsuura. However, the shop floor at R&G Precision looked different four years ago from how it is today. Enzo Chiarelli from R&G Precision Engineering Ltd says: “We recall looking back to our first multi-pallet lights out machine and thinking back to when we were first looking at it – we were thinking ‘this is never going to work’. Now, we are predominantly lights-out multi-pallet machining, and the plan for the next 3-4 years is to swap more single spindle and single pallet machines for the multi-pallet variants.” “It’s nice to sit at home now and think, ‘I am making money.’ With the RiMM software, you can control that. So, when your team says the machine was running all night, you can come in and look at the RiMM system and say – oh yeah, it was running at 2am this morning.” Thinking back to 2020, Enzo recalls: “I remember thinking, ‘What have I done? It’s such a big investment with lights-out machining. It’s worked, and it’s a journey we’re so glad we started. It’s exciting and gives us a vision of where next.” With a machine shop filled with Matsuura machines like the MX330, the company was nervous about diving into ‘lights-out’ machining. Recalling what the company has learnt, Enzo says: “I did a lot of research, we had to weigh up the pros and cons. The pros are running when nobody is here with multiple set-ups. The cons are all around making sure you got the process right – as you can have tool breakages, blockages, you could have coolant issues and a multitude of other variables – and that is always a worry.” “We also had to think ‘how do you start’ – do you go slowly and build up or go in straight at the top? However, it was all about learning from the first machine for us and learning about how to get to a complete lights-out process that gives you the confidence to say, ‘OK, I know what I’m doing now. I have to prove out every job during the day for 2 to 3 weeks before swapping out and making the switch – and that is what we did.” Now with 8 Matsuura machines, Enzo recalls the first machine: “That was an ES-450HII machine that is still running, and for us, that was an investment in a company that we’d never done business with before. The sales rep pushed me towards lights-out machining, which is how we got to eight machines.” The company progressed to buying the Matsuura MX330 multi-pallet machines acquired for a batch of work the company had at that time. However, that was two years ago, and the company has since changed direction. As Enzo adds: “The Matsuura MX330 machines were bought for smaller components in repeat orders we were doing at that time. That work increased, so we bought a second MX330 with 10 pallets. However, Dominic from Matsuura asked us why another MX330 was needed.” “We sat down and showed Matsuura the portfolio of parts in the pipeline, and he instantly said no, you need a MAM. So, we purchased a MAM72-63V, and it worked. Now, we will continually show Matsuura the portfolio of parts we have, and they will tell us what machine to buy – and it works well.” “The contract we bought the MX machines for is completely separate from a new contract that has arrived. The first contract ran for four years and continues to run, where we machine repeat orders for 50 to 100 parts a month. The other contract we had to invest in with another five Matsuuras is a 15-year aerospace contract that will run until 2035. That is a contract where I sat with Dominic and said, ‘You have to advise me on whether we need to invest in the MX range, the MAM machines or other models.’ I’m glad we took his advice, we opted for a MAM35 and a MAM63, which also gave us a size difference. On the MAM63 machine, we can do larger parts and a mix of smaller parts. On the multi-pallet machine, we can do everything, and we have no downtime at all.” /episode/index/show/mtdmag/id/38155130

Revolutionising factory automation with intelligent measurement solutions 09/10/2025

Revolutionising factory automation with intelligent measurement solutions According to Pralhad Thapa, Department Manager at Mitutoyo Europe, an expert in dimensional metrology and automation: “We are confident we can address these issues for our customers, providing unattended measurement solutions that are easy to operate and available at a reasonable price.” In a presentation, it was this opening gambit that embodies both the philosophy of the new SmartMeasure AL system and Mitutoyo’s commitment to precision. Building upon decades of expertise in CMMs, this turnkey solution addresses the fundamental pain points expressed by customers across diverse industrial sectors. Predicting the Market Demands The persistent shortage of skilled manpower has created operational bottlenecks, whilst increasing quality demands have elevated the importance of precision measurement. Traditional approaches that rely heavily on manual intervention and specialised expertise are proving inadequate in meeting the evolving demands in the face of a skills crisis. Mitutoyo’s SmartMeasure AL emerged from extensive customer consultations across European markets. Industry feedback consistently highlighted specific requirements: systems capable of easing labour shortages, reducing human error, providing stable measurement capabilities, supporting high-mix production environments, and enabling unattended operation during night shifts and breaks—all whilst maintaining cost-effectiveness. The industry isn’t asking for much there, then…. Developing SmartMeasure AL as a standardised product, rather than a bespoke project-based solution, represents a significant strategic shift. Thapa explains this fundamental change: “Our goal with SmartMeasure AL is to develop this fully automated solution as a product, so that our customers can order it from our website, our B2B shop, or through other means. This approach enables reduced development costs, shorter delivery times, and more competitive pricing compared to traditional custom automation projects that Mitutoyo has delivered over the past three decades.” System Architecture and Core Concept SmartMeasure AL employs a three-component architecture comprising a CMM, an industrial robot system, and supporting infrastructure including racks, pallets, fixtures, sensors, and integrated software. This modular philosophy allows for flexible configuration according to specific customer requirements whilst maintaining standardisation benefits. The system’s operational principle centres on a 12-part pallet rack configuration. When an operator initiates the measurement cycle, the integrated robot retrieves parts from designated positions, transports them to the CMM and returns them to the rack with a clear indication of pass/fail status. This automation eliminates the need for continuous operator supervision whilst maintaining measurement accuracy and traceability. Central to the system’s intelligence is Mitutoyo’s ESPRIT software platform. Unlike conventional automation systems that rely on PLCs requiring specialist expertise, ESPRIT provides an intuitive graphical user interface accessible to operators with basic technical knowledge. As Thapa emphasises: “We really focused on developing the graphical user interface, because we know operator knowledge is limited and the market has a skills deficiency.” Technical Specifications SmartMeasure AL demonstrates versatility through its compatibility with multiple Mitutoyo CMM models, including the CRYSTA-Apex S series (544, 574, 776, 7106, and 9106 configurations). The robotic component utilises FANUC CRX series of collaborative robots, available in two payload configurations: CRX-10iA/L and CRX-20iA/L with 10 and 20kg payload, respectively. This dual-option approach ensures optimal matching between robot capability and workpiece requirements. Importantly, Mitutoyo maintains openness to alternative robot manufacturers, allowing customer preference integration where requirements exist. Advanced Software Features and Capabilities The ESPRIT software platform incorporates several features designed to enhance productivity and operational efficiency. Multiple part measurement capability allows simultaneous measurement of several small components within a single 250 by 250mm pallet, particularly beneficial for manufacturers where part sizes permit batch processing. The re-measure functionality demonstrates the system’s intelligence. Following overnight automated measurement cycles, operators can selectively re-measure only those parts flagged as non-conforming, eliminating unnecessary repeat measurements of acceptable components. RFID technology provides part tracking and traceability where each component’s measurement history can be automatically logged and integrated with broader quality management systems to provide audit trails. Real-time connectivity capabilities facilitate integration with external systems, including ERP platforms and manufacturing execution systems. This connectivity supports Industry 4.0 initiatives and enables data-driven decision making. Closed-Loop Manufacturing Integration SmartMeasure AL’s closed-loop manufacturing capability represents a significant advancement in process control. The system automatically analyses measurement data and calculates necessary tool offsets for upstream CNC machining operations. When deviations are detected, ESPRIT software automatically transmits correction values to the relevant CNC machines, enabling real-time process optimisation. This closed-loop approach reduces setup times and scrap rates through proactive process control. The automatic feedback mechanism minimises the time between problem detection and correction implementation, crucial for maintaining tight tolerances in high-volume production environments. Competitive Advantages SmartMeasure AL’s primary competitive advantage lies in its product-based approach rather than project-based delivery. Customers can order complete systems through standard commercial channels, including Mitutoyo’s B2B platforms, enabling predictable pricing, standardised delivery schedules, and reduced implementation complexity. Thapa notes the market reception: “The feedback has been very positive. When customers came and saw our product, they said, ‘Unattended measurement. The GUI is very simple to use, and an operator with minimum knowledge can operate this fully automated system.’” The system’s compact footprint addresses space constraints, and despite incorporating a complete CMM, robot system, and part handling infrastructure, SmartMeasure AL requires minimal floor space. Cost-effectiveness extends beyond initial capital investment. The elimination of PLC programming requirements reduces implementation and maintenance costs, whilst the intuitive ESPRIT interface minimises operator training requirements. Future Development and Expansion Mitutoyo’s roadmap for SmartMeasure AL encompasses expansion across the company’s broader product portfolio. Future developments will extend automation capabilities to laser measuring machines, contour and roundness measuring systems, and surface texture measurement equipment, creating a comprehensive automated measurement ecosystem. Thapa confirms: “We will continue to develop this product and expand to support other products from Mitutoyo. We will continue to support our customers in the field of factory automation, help them and understand their pain points and see where Mitutoyo technology can increase productivity.” Conclusion Mitutoyo’s SmartMeasure AL represents a paradigm shift in automated measurement solutions. By addressing critical industry challenges, including skilled labour shortages, quality demands, and operational efficiency requirements, the system provides a comprehensive solution. The product’s success lies in its synthesis of proven measurement technologies, intelligent software platforms, and flexible automation capabilities within a standardised, cost-effective package. /episode/index/show/mtdmag/id/38155125

Precision tools driving EV and hybrid composites manufacturing 09/10/2025

Precision tools driving EV and hybrid composites manufacturing At the core of lightweight, high-speed and energy-efficient electric and hybrid vehicles, composite materials play a crucial role in manufacturing advanced components. However, working with composites demands more than just selecting the right materials; it requires a new generation of precision tooling. The Composites Challenge Composites such as carbon fiber-reinforced polymers (CFRPs) and glass fiber composites (GFRPs) are not easy to work with. Their multi-layered structure, fiber orientation and abrasive nature make them resistant to traditional machining techniques. Unlike metals like steel, composites don’t deform, they fracture. That means every cut must be calculated, every edge protected, and every tool enhanced. “The challenge with machining composites is that your cutting tool needs to be both sharp and abrasion-resistant at the same time. It is a delicate balancing act,” said Chris Stewart, Kennametal Key Account Manager. Diamonds are Forever Diamonds aren’t just a luxury; they are essential in composites machining. One of the most significant innovations from Kennametal is the introduction of KBDM PCD Face Mills. These polycrystalline diamond tools are a high-density platform designed for faster machining cycles and precise surface finishing of composite components. Their extreme hardness and thermal stability enable them to stay sharp, providing clean, delamination-free finishes on critical parts such as battery enclosures, structural panels, and motor housings. Additionally, the KD1400™ and KD1425™ grades, when combined with the cutter bodies, offer improved wear resistance and edge strength. Drilling Stacks Drilling into composites—especially when combined with metal layers—requires tools that can manage heat, resist wear, and maintain hole integrity. Kennametal’s DAL drills can be used in all combinations of stacks such as CFRP-Ti-Al, CFRP-Ti, CFRP-Al, and also straight Ti or Al. They feature a double-angle point design and minimise burrs when exiting the metal side of the stack. Routing with ROCO Routing operations, which are vital for trimming, profiling, pocketing, side milling, and slotting composite parts, have also experienced significant innovation. Kennametal’s ROCO burr router geometry pushes cutting forces both upward and downward, reducing delamination during side milling and slotting. Meanwhile, the down-cut routers from Kennametal produce clean top-surface finishes by pushing chips downward, making them ideal for visible parts where aesthetics and surface quality are important. “ROCO routers have seen great success across a range of composite materials and applications,” said Katie Myers, Kennametal Marketing Product Manager. “Our geometry paired with our new KCC05A CVD diamond coating grade is providing exceptional tool life and the ability to run at higher cutting parameters.” Additive Manufacturing in Tool Design Manufacturers are also leveraging additive manufacturing to create custom tool bodies with internal cooling channels and optimised weight distribution. These 3D-printed tools are lighter, more rigid and capable of handling complex geometries, especially in deep cavity applications like electric motor housings. For example, Kennametal’s 3D printed stator bore tool for machining aluminium e-motor housings is capable of machining three large diameters in just one operation. The tool features airfoil-shaped arms with internal coolant channels, enabled by additive manufacturing, which improves chip evacuation and cooling. It also includes carbon fiber components to further reduce weight and improve handling. Additionally, Kennametal’s RIQ inserts are ideal for machining large diameters, while the RIR inserts deliver precision for smaller diameters. When paired with Kenionic™ tool holders, these inserts form a high-performance reaming solution. Beyond the Shop Floor The influence of these tooling innovations extends far beyond the shop. By enabling the efficient processing of composites, advanced tools contribute directly to vehicle performance and sustainability. Lighter components reduce energy consumption and extend battery life. Precision machining minimises material waste and rework. And smarter tools help manufacturers scale production while maintaining quality and consistency. Some of the latest tools are embedded with smart sensors that monitor temperature, vibration and wear in real time. These tools communicate with CNC systems to dynamically adjust cutting parameters, reducing the risk of tool failure and ensuring consistent part quality. In high-volume EV production environments, where production time and repeatability are paramount, this level of intelligence is becoming a real competitive advantage. Longevity in Composites Tooling In high-demand manufacturing environments, tool longevity isn’t just a convenience; it’s a requirement. The future of composites tooling lies in deeper integration with digital manufacturing ecosystems. As EV and hybrid vehicles become more sophisticated, the tools that shape them must also evolve to become faster, smarter and more adaptable. Tooling is no longer a behind-the-scenes operation; it’s now a critical part of the overall metal cutting strategy. “Innovation is our priority,” said Myers. “With all of the advancements being made in composite materials, our tools are constantly evolving to continue to provide a high level of performance and reliability in materials outside of the metals we’ve traditionally worked with.” Conclusion With advanced solutions like PCD face mills, stack-optimised drills, innovative router geometries and additive-manufactured tool bodies, manufacturers can meet the growing demands of composites machining head-on. The proper tooling just doesn’t cut it anymore. It must accelerate production, improve quality and support sustainability. /episode/index/show/mtdmag/id/38155100

Power skiving for automotive’s future 09/10/2025

Power skiving for automotive’s future According to the International Energy Agency’s (IEA) World Outlook, the clean energy transition and the rise of electric vehicles (EVs) could lead global demand for fossil fuels to peak before 2030. As nations worldwide shift away from fossil-fuelled engines and towards an electric future, automakers are making a shift of their own, starting with their machine setups. Here, Swetapadma Mohanty, Senior Development Engineer, Gear Machining at Sandvik Coromant, explores the machining methods that will prove key to the automotive industry’s electric future. Another prediction made by the IEA is that, by 2030, the global electric car stock will expand to almost 350 million vehicles. That’s more than 60% of vehicles sold. To accommodate the rise in EVs, automakers are turning to alternative machining methods. One such method is power skiving. Common gear machining challenges Before diving into power skiving and its machining considerations, let’s think about the common challenges associated with gear machining. The machining of gears for internal combustion engine (ICE) vehicles and EVs can differ in certain aspects due to the distinct characteristics and requirements of these two types of vehicles. For instance, while ICE vehicles often have complex multi-speed transmissions to optimise power delivery, EVs typically have a single-speed or limited number of fixed gear ratios. Other distinguishing features include torque characteristics, noise and vibration considerations and weight and size constraints. Machining gears, for any vehicle type, presents several machining challenges. To ensure proper meshing and transmission accuracy, gears require tight tolerances with high machining precision. Gears must also be designed to minimise noise and vibrations during operation in order to maintain batch consistency and ensure tool maintenance is key to achieving high production volumes. Popular gear machining methods include hobbing, milling, shaping and broaching. However, these methods often have limitations such as lower flexibility in handling various gear types, longer cycle times and challenges with specific gear geometries. Hobbing is particularly popular for cutting spur and helical gears and is most suited to smaller production runs and for producing gears with various tooth profiles. For mass production, gear shaping is a preferred method as it can achieve high dimensional accuracy in shorter cycle times. But these machining methods are incredibly specialist. Broaching and hobbing, for instance, must be carried out on a specialist machine, with a totally different machine required for shaping. Then there are all the other steps required for successful gear production — milling, turning, finishing, quality inspection and so on. What does that mean for manufacturers? Multiple machines set ups, limited flexibility, lengthened lead times and a costly machining process can all be consequences of a gear machining process that’s not catered to our increasingly electrified world. Enter power skiving. If we’re to get 350 million EVs on our roads by 2030, automakers must turn to machining methods that can accommodate. This is where power skiving comes into play. As a continuous process that uses a specialised cutting tool to remove material from a gear blank, power skiving boasts several benefits over traditional methods like hobbing and shaping. First, power skiving typically provides higher precision and tighter tolerances compared to traditional process. It’s well-suited for producing gears with complex profiles, including helical gears and non-standard shapes. Traditional process may have limitations in achieving intricate tooth forms, especially when dealing with high helix angles or specific gear geometries. Generally, power skiving is faster than traditional gear machining processes and, as it removes only the necessary material to form the gear teeth, the waste produced is minimal. A core driver for its use in EV production is power skiving’s flexibility — it’s suitable for various gear applications, including those with specific performance requirements. Manufacturers can therefore adapt to different gear types more easily than they can with traditional machining methods. With reduced set ups in multitask machines with power skiving, higher quality can be reached. Crucially, power skiving is performed on a multitask machine. Performing multiple activities on a single machine will reduce set up times, improve accuracy, increase throughput and streamline programming. For those currently using multiple machines to execute traditional gear machining methods, however, upgrading to a multitask machine for power skiving requires some investment. It will be up to manufacturers to weigh up the pros and cons of their machining set-up, but there’s one thing we cannot deny — the pace of electrification isn’t going to slow down. To compete in an evolving, competitive market, flexibility, adaptability and process efficiency will be fundamental. Tool selection If power skiving is the right machining method for automotive’s future — what are the right tool choices? Let’s start with the gear milling tools themselves. Tools should have tight tolerances to ensure accurate machining and to produce gears with uniform quality. A good gear milling tool should also be heat-resistant to maintain its cutting performance and prevent premature wear, with a design that facilitates proper chip evacuation to ensure smooth cutting operations. The CoroMill®178 and CoroMill®180 family of gear milling tools meets those expectations. For internal and external gears, capable of machining both cylindrical spur and helical gears from roughing to finishing, CoroMill® 178 is a key part of a successful power skiving setup. It is best used in applications where high-volume, high-rpm machining with long tool life is required, while CoroMill® 180 is ideal for general use on shoulders or small diameters. These tools offer the highest tool accuracy, regarding run-out and pitch, compared with indexable tools, providing a superior finishing profile of the gear and spline. In one customer success case, by replacing a traditional process with power skiving using CoroMill® 178, cutting time was reduced and tool life increased significantly. With annual growth in production, the customer was able to save over 100 hours of machining time each year. It’s not just about cutting tools with Sandvik Coromant. Customers receive tooling and application support, along with a service offering that includes technical feasibility consultancy. For example, our ESCO software is another vital component of our power skiving portfolio, enabling high-quality and precise production of power skiving tools. InvoMilling® is a vital part of Sandvik Coromant’s gear machining portfolio. As part of the CoroPlus® Tool Path software, InvoMilling® is a process used for machining external gears, splines, and straight bevel gears with exceptional flexibility. This makes it highly suitable for small batch production and situations where short lead times are essential. The solution takes advantage of multitasking machines and machining centres’ capability to produce various gear profiles using the same set of tools. As the world prepares for an electrified future, automakers must consider their manufacturing techniques. While traditional gear machining methods have long served the industry, thriving in a changing and increasingly competitive environment requires flexibility. Power skiving provides that flexible, adaptable approach — all while delivering finished components of the highest quality. As market leader, Sandvik Coromant is also focusing on high-level sustainable Power skiving tools and reducing CO2 footprints. /episode/index/show/mtdmag/id/38155080

Motorsport subby takes pole position 09/10/2025

Motorsport subby takes pole position 2025 is already proving to be a memorable, standout year for leading precision motorsport subcontract specialist, Northants Precision Ltd. In addition to acquiring two more DN Solutions’ Lynx 2100 lathes from Mills CNC, the company has successfully completed its relocation to larger premises, increased its headcount, and secured new machining contracts. Led by owner and Managing Director Daniel Green, Northants Precision continually aims for excellence. The machines, an 8” chuck, long-bed Lynx 2100LMB with driven tooling, and a 6” chuck, 2-axis Lynx 2100A, were installed at the company’s new 3500sq/ft. manufacturing facility in Kislingbury, Northampton, in January and June 2025. Both machines are equipped with powerful, high-torque spindles, servo-driven turrets, rigid roller-type LM guideways, and hydraulic tailstocks. The Lynx 2100A offers a maximum turning diameter of 350mm and a turning length of 330mm with its 15kW/6000rpm spindle and 12-station turret, while the long-bed Lynx 2100LMB provides a 300mm turning diameter and 510mm turning length, featuring a 15kW/4500rpm spindle, 12/24-station turret, and 6000rpm driven tooling capabilities. The new machines are positioned adjacent to four previously acquired Lynx lathes, a Lynx 2100B (2022), a Lynx 2100MB (2021), a Lynx 2100LMB (2021) and a 10-year-old Lynx 220LSY. Together, these six FANUC controlled machines, three with driven tooling capabilities, provide Northants Precision with a formidable in-house turning and milling resource. All feature the advanced FANUC iPlus control with 15” touchscreen iHMI, making them ideal for meeting the accuracy needs and fast turnaround demands of motorsport customers. Since installation, the new Lynx lathes have been machining a range of small, complex, and high-precision engine, chassis, sub-frame, and gearbox components for F1, WEC (World Endurance Championships), WRC (World Rally Championship), and supercar customers. Parts machined on the Lynx lathes are typically washers, nuts, bolts, and top hats. They are characterised by tolerances of +/-5 microns on specific features, a flatness of 0.01mm, and strict surface finish requirements. These parts are machined in small-to-medium batches from solid bar stock. The primary materials processed include heat-treated stainless steels (13-8PH and MP35N), titanium 6242/6246 alloys, and aluminium. Part cycle times range from just a couple of minutes up to 10 minutes, and to ensure accuracy, concentricity, and flatness, parts are securely held using Hainbuch collet chucks. Daniel Green: “Machining and supplying hundreds, sometimes thousands, of identical high-precision and performance-critical parts from hard, difficult-to-machine materials to exacting quality standards is commonplace for us. But to achieve this consistently requires reliable, high-performance machines and proven CAD/CAM, machining, and inspection processes. We have invested significant resources to ensure we have all of these in place.” Northants Precision regularly monitors its performance to identify potential production bottlenecks and address them before they become problematic. The company’s success in securing small part machining contracts from new and existing customers, including recent contracts won directly with F1 racing teams, prompted capacity reviews at the end of 2024 and during Spring 2025, ultimately leading to orders for two new machines. Daniel Green continues: “F1, and motorsport in general, is demanding and challenging. You always have to be ‘on top of your game’ and constantly meet customers’ quality and lead time requirements from day one. Failing to do so quickly tarnishes your reputation and means your days as a supplier in the sector are numbered. Our positive experiences with DN Solutions Lynx 2100 lathes and Mills CNC’s pre and after-sales services meant that, on both occasions, we made Mills our ‘first port of call’, ultimately investing in the new Lynx 2100A and Lynx 2100LMB.” A typical machined part is an engine housing washer component made from 10mm diameter pre-cut titanium bar stock supplied in 42” lengths. These parts are machined to completion in medium-sized batches (600-off) using two of Northants Precision’s Lynx 2100 lathes positioned opposite one another to create a flexible manufacturing cell, operated by one member of staff. Front-end ID and OD turning are performed on a Lynx 2100 (two-axis) lathe, where a bar puller ensures a reliable process and continuous production. After the initial operations, which take about 2 minutes per part, the semi-finished parts are individually loaded into the Lynx 2100LM for back-end processing. This involves machining an angled groove or chamfer on each part, which takes approximately 30 seconds. Says Daniel Green: “We strive for excellence across the board. Everything we do, from our in-house CAD/CAM, machining and inspection to any outsourced processes - is integrated and carefully controlled.” /episode/index/show/mtdmag/id/38155060

Keeping the automotive industry moving 09/10/2025

Keeping the automotive industry moving In automotive manufacturing, speed and precision aren’t luxuries—they’re survival tools and ‘every turn of the spindle counts’. Threading, grooving, and deburring may seem like small elements in the bigger picture of vehicle production, but get them wrong, and entire lines grind to a halt. Few tooling providers have tuned their offering so tightly to the demands of this environment as VARGUS. With its VARDEX threading systems, GROOVEX grooving solutions, and SHAVIV hand deburring tools, VARGUS has positioned itself as a crucial partner to the automotive industry and the supply chain around the globe. From transmission cases to ‘e-axle’ housings, automotive driveline components depend on precise threads and flawless sealing grooves. The VARDEX threading tools handle high-volume work in ductile iron, aluminium, and alloy steels with remarkable repeatability, whilst the GROOVEX tools can cut retention and O-ring grooves with predictable and stable tool life—keeping scrap rates low in critical sealing areas. This process stability is critical in high-output environments; a single defective groove or off-spec thread can trigger costly line stoppages, and manufacturing sites running modular VARGUS systems frequently report reduced tooling SKUs, faster changeovers, and fewer burr-related rework and post-operation hand finishing. The rise of electric vehicles has reshaped machining challenges with the arrival of thin-wall battery trays, intricate coolant channels, and delicate motor housings. Thread milling is known to minimise cutting forces, which protects lightweight aluminium structures from distortion. It is here that the compact GROOVEX tools from VARGUS enable intricate sealing features in cramped, high-value components. The result is faster adaptation to evolving EV designs without complete retooling. Manufacturers notice the difference with predictable tool life that reduces unplanned production stoppages and makes OEE more stable. Consistent quality is also maintained with micron-tight profiles maintained over long runs. Additionally, end users have simplified inventory with fewer unique SKUs for threads and grooves. In addition to this, VARGUS has a range of digital tools available through its application software that has become a secret weapon for engineers in APQP and PPAP phases. With it, teams can select the right tool by standard, pitch, and material and also access proven cutting data with the added benefit of generating tool strategies quickly with cutting ‘trial-and-error’ time before production launch. Automotive manufacturing is a balancing act of volume, accuracy, and efficiency. VARGUS’s precision tooling and digital support help manufacturers keep that balance, turning once-fragile processes into robust, repeatable production steps. In a sector where every second matters and quality is king, VARGUS has become more than a tooling supplier—it’s a partner in keeping the wheels of industry turning. The latest addition to the company’s portfolio is the new VARGUS bell shape tool, a high-speed external threading system designed for the automotive and valve industries. Suitable for threading manifolds and fuel filters with extreme precision and cycle times, it features short toolholder movements, multi-flute toolholders, easy clamping, a dovetail clamping system and an enclosed holder structure. All this delivers shorter cycle time and higher productivity, faster feed rates, convenient insert assembly, improved rigidity and accuracy and much more. /episode/index/show/mtdmag/id/38155045

High-precision grinding is an art 09/10/2025

High-precision grinding is an art Starting a business requires risk-taking. “It’s like a motorcycle race. If you don’t want risks, you might miss your chance to win,” says Randy Gevers, CEO of GRT-Tech. Passionate grinder Randy Gevers knows his stuff. Before founding his company, he enjoyed years of success in motorcycle racing. But his success story begins with his father, Antoon Gevers, who instilled a love for engines and metalworking, especially grinding. After years of working together, the Gevers family took the plunge in 2016 and started their own business. The first machine Randy bought was a conventional grinder, with others quickly following. Fittingly, their initial customers came from the KTM community, as the family had built an extensive network through racing. Today, customers from aerospace, medical technology, tool and mould making, trust the Gevers, alongside navy suppliers and semiconductor industry suppliers. “Theoretically, we could survive on semiconductors alone,” says Randy. “But a company shouldn’t become dependent on one sector.” The range of materials at GRT-Tech extends from steel, various stainless steels, brass and copper to ceramics and plastics. Typically, small batches of up to around 50 pieces are manufactured, but individual parts and prototypes are also produced. Precision Demands Better Equipment Randy quickly realised that machining complex workpieces, such as those used in tool and mould making or medical technology, reached its limits with conventional grinding machines. After moving to their current location in 2018, he purchased a powerful, used KELLENBERGER KEL-VARIA CNC universal cylindrical grinding machine. Right from the start, we received many requests for grinding complex workpieces,” says Randy. “But we could only accept around 10% of them. I couldn’t, and didn’t want to, continue like that.” The decision wasn’t difficult—both Gevers knew and valued these machines from their previous employer. The KEL-VARIA, a predecessor of today’s premium KELLENBERGER K1000 series, embodies the highest machining and surface quality. It has very high static and dynamic rigidity that ensure the machine delivers precise and efficient operation. Expanding Capabilities Following a positive experience, another KELLENBERGER machine was quickly shipped to Heeswijk-Dinther: a universal internal and external cylindrical grinding machine KELLENBERGER K100. René van der Peet from BMT Bridgeport Machine Tools, which represents KELLENBERGER in the Netherlands, served as a consultant. The KELLENBERGER K100 is available with centre distances of 1,000/600mm and a 200mm centre height, designed for workpiece weights of up to 150kg. High grinding wheel drive power ensures increased productivity, while the Z-guide maintains high profile accuracy. The C-axis with direct drive offers greater precision in non-circular grinding. Randy selected the longer 1,000mm overall length for greater flexibility in part sizes, along with a grinding head variant featuring two external grinding spindles, one internal grinding spindle, and a tactile measuring head. The high-frequency spindle, with a speed range of 6,000 to 40,000 rpm, includes an internal coolant supply. “I’m fascinated by the machine’s high, reliable accuracy. Added to that are my years of experience, which ultimately makes the difference for the customer,” says Randy, adding with a laugh: “A machine can’t advise on how best to manufacture a workpiece.” Mastering Complex Challenges Challenging workpieces are a daily task at GRT-Tech, such as components that combine copper and cast iron with the roughness of less than 0.15µm. “We could achieve 0.05µm, but that’s not necessary in this application,” explains Randy. “Cast iron is very porous and brittle; the grinding stone clogs quickly and must be dressed continuously, but not too often. It’s about finding the right balance. The more experience and sensitivity a grinder has, the more precise such workpieces will be. This component is very expensive due to material combination and upstream processes like turning, milling and EDM. The grinding process must be perfect first time.” “The more complex the workpiece, the higher the precision requirements, the greater my motivation to perfect it,” says Randy. He simply loves a challenge—no longer at the racetrack, but with his machines, for his customers’ benefit. /episode/index/show/mtdmag/id/38155035

Funding to accelerate the low-carbon switch 09/10/2025

Funding to accelerate the low-carbon switch While car production is slow, factory activity is building strongly to decarbonise automotive as carmakers target 2030 for going all-electric. Subcontractors could be eligible for the new DRIVE35 government programme, which could offer some companies grant funding to help them lighten and decarbonise their products, says Will Stirling. Based on cold numbers, little has changed in the automotive sector since MTD’s last report in March. In 2024, UK vehicle production was at its lowest level since 1954, excluding the disruption from Covid. And in the first half of this year, carmakers posted another 12% drop to just 417,200 vehicles manufactured, the lowest number since the early 1950s. The causes are well-known: weak global demand and the cost of the transition to low-carbon vehicles. But SMMT, the motor industry business group, is forecasting a bounce back in 2026 and there is evidence from several quarters that they are right. First, note that what we see on the roads is not an accurate reflection of changes happening in the factories of Britain. Only 4.75% of the 34 million cars on UK roads are fully electric, rising about one per cent a year, according to EV consultancy Zapmap. For new sales, by July 254,666 new fully electric cars had been sold, a 21.5% market share of all new cars registered this year and 57,745 more fully electric cars than were sold at the same point last year. The proportion of new electric cars has grown from 11.6% in 2021, to 19.6% in 2024 – so, decent if unspectacular progress, reflecting buyers’ reticence with cost, and charge point/range anxiety. A new EV grant and falling prices could boost sales. Many buyers lacked incentives until now. Lower-cost EVs from Renault and Chinese brands, along with a £3,750 Electric Car Grant and EV Chargepoint Grant, might increase sales,” says Professor David Greenwood. However, the full grant applies only to cars with the lowest CO2 footprint; others receive a reduced £1,500 discount. Currently, no UK-made or sold cars qualify for the full grant, experts at BBC Top Gear say. Manufacturing activity is different to cars on the road, however. In the UK, about 80% of what we buy is imported and 80% of what we make is exported, and there are some very different drivers at play affecting manufacturing. Across the board, EV and low carbon vehicles and their component makers are ramping up fast. Jaguar Land Rover recently stopped making the XE, XF, and F-Type models as it shifts to an all-electric ‘reimagine’ brand, reducing production at Jaguar sites temporarily. However, this should be offset by Nissan increasing output in Sunderland, including new models like Qashqai, EV Leaf, and Juke, despite closures elsewhere. Overall, manufacturing volumes are expected to rise later this year, with Nissan among several automakers investing in factory expansions. Factory and product investments pick up UK Export Finance has underwritten a £1bn export development guarantee to Ford UK, aimed at supporting Ford’s global transition to EV production. The loan, provided by Citi and several lenders, helps fund aspects of its transformation to EV powertrains, and it follows a £380m investment in its Halewood manufacturing plant, to switch from producing transmissions to electric motors. Steel frames have been erected at the site of Agratas’s new battery gigafactory in Somerset, marking the start of the next phase, the vertical build. 17,000 piles had been placed in the ground by the end of June. Agratas says that 100% of the steel used for the build is sourced from British suppliers. Astemo UK, a subsidiary of Japanese car parts maker Astemo, will build a new production line for inverters for next-generation EVs at its Bolton plant. The total investment, which includes support from government’s Automotive Transformation Fund, is £100 million and it will secure an estimated 220 jobs. Production is scheduled to begin in April 2027. Rolls-Royce will be fully electric by 2030, starting with the Spectre coupé, followed by an electric SUV in 2027 and a new luxury saloon replacing the Phantom. They are building a £300m extension to the Goodwood factory to increase capacity and support electric vehicle manufacturing, investing in future demand. The government launched DRIVE35, a long-term £2.5bn programme supporting low-carbon vehicles. It includes £2bn in funding to 2030 and £500m for R&D to 2035, a ten-year commitment to UK automotive innovation. Here’s the good bit: subcontract manufacturers that make car parts and are focused on lightweighting are ineligible for DRIVE35 funding. Three main funding priorities are: supporting innovation, accelerating start-up and enabling transformation – so if a company’s work fits broadly into any of those categories, it has a chance of winning an award. How are SME metal forming companies responding on the ground? “Full electric transition is still way off, but a lot of our members have already started to adapt what they do to supply into the new generation of vehicles – many of them with significant success,” added Stephen Morley, President of the Confederation of British Metalforming. His organisation represents more than 200 companies involved in fasteners, forgings, pressings and precision metalwork, a vital part of the industry that makes products that go into many critical automotive applications. “There are many opportunities and UK firms are renowned for their resilience and ability to pivot to make the most of them. But Steve adds “I’m afraid there is a big ‘but’ though.” “We are achieving all of this despite a tsunami of external factors out of our control, some of which are self-inflicted by a government that is supposed to be backing industry. The change in steel safeguarding quotas - introduced at the drop of a hat by Business Secretary Jonathan Reynolds in July - was against Trade Remedies Authority (TRA) and has caused major disruption and financial hits to our sector. Our members have reacted furiously to this decision.” While the ambition is grand, regulations that hamper SME efficiency and the disconnect between government and business pervades and risks slowing any recovery as the electric shift beds in. Expect car production to rise in 2026 While the numbers and order books today are low, for many, there are legitimately brighter days ahead for the car industry. The UK has a beneficial tariff rate (relative to the EU) for exporting cars to the US of 10%, but this applies only to the first 100,000 vehicles imported into the US. Beyond 100,000, the higher tariff of 27.5% applies; however, it’s still a relative boost for UK-made luxury brands. Prof Dave Greenwood adds, “The measures announced for the automotive sector in the industrial strategy (that include reduced energy costs, R&D grants, Investment Zones, etc) should all position well for longer-term future growth in manufacturing.” /episode/index/show/mtdmag/id/38155020

Cutting-edge solutions for turbocharged engines 09/10/2025

Cutting-edge solutions for turbocharged engines In the rapidly evolving automotive industry, turbocharged engines have become increasingly common due to their ability to improve engine performance, fuel efficiency, and reduce emissions. However, machining the high-precision components of a turbocharged engine presents considerable challenges. ISCAR offers cutting-edge solutions specifically designed to meet these challenges, ensuring superior performance, efficiency, and cost-effectiveness. Turbocharged engines typically require the machining of complex geometries and hard-to-cut materials such as titanium alloys, heat-resistant stainless steel, and high-temperature alloys. These materials are chosen for their durability and capacity to withstand extreme conditions, but are notoriously difficult to machine due to their hardness and propensity for rapid tool wear. Achieving the high levels of precision required for turbo engine components is crucial for optimal engine performance. Engine downsizing is a prevailing trend in the automotive industry, with turbochargers now commonly found in both large diesel and gasoline engines. Turbochargers can significantly boost an engine’s horsepower without a substantial increase in weight, providing high performance and additional benefits for modern vehicles. However, turbochargers present challenges for original equipment manufacturers (OEMs), as they must endure extreme operating conditions, very high temperatures, and high-speed revolutions per minute (rpm). These demands drive OEMs to explore new materials and technologies. ISCAR’s extensive global industry experience positions the company at the forefront of providing higher productivity, profitability, and performance gains. In the field of turbochargers, ISCAR presents innovative solutions and stable processes for turbocharger-related components. ISCAR views OEMs as high-priority customers and is committed to building long-term partnerships. The company’s goals include recommending efficient and economical solutions, delivering high-quality products, and providing long-lasting support. ISCAR has developed a comprehensive range of cutting tools and solutions specifically designed for the challenges of machining automotive turbo charged engines. These solutions focus on enhancing productivity, extending tool life, and achieving exceptional surface finishes, all while maintaining cost-efficiency. Engineered for high-feed and high-efficiency milling, ISCAR’s indexable milling cutters are ideal for both roughing and finishing operations (Figure 1). Their robust design ensures stability and precision, even in demanding machining conditions. The use of advanced geometries and coatings helps mitigate issues related to high temperatures and tool wear. Designed for machining hard materials, ISCAR’s endmills offer exceptional durability and precision. Available in various geometries and coatings, ISCAR’s solid carbide endmills cater to the specific needs of turbocharged engine component manufacturing, providing solutions for high-speed and high-accuracy applications. ISCAR offers a wide range of turning tools optimised for machining high-temperature alloys and other challenging materials. These inserts are designed to minimise tool wear and provide excellent chip control, ensuring smooth and efficient machining processes. The advanced insert geometries allow for reduced cutting forces, contributing to improved tool life and surface finish. Grooving operations are critical in the manufacturing of turbocharged engine components, where precision and surface quality are paramount. ISCAR’s grooving tools are designed to handle the rigorous demands of machining hard-to-cut materials and complex geometries. ISCAR offers a wide range of indexable grooving inserts tailored for machining high-temperature alloys and other challenging materials (Figure 2). These inserts are engineered to deliver exceptional wear resistance and superior chip control. The inserts are available in various geometries and cutting edges, optimised for different grooving applications, ensuring smooth and efficient material removal. ISCAR’s grooving holders are designed to offer maximum stability and accuracy during machining. The holders feature durable clamping mechanisms to securely hold the inserts, reducing vibrations and extending tool life. Their innovative design allows for easy insert replacement, minimising downtime and boosting overall productivity. ISCAR uses state-of-the-art coatings on its tools to improve performance. These coatings deliver better wear resistance, lower friction, and enable higher cutting speeds, thereby boosting productivity and prolonging tool life. Coated tools also help achieve smoother surface finishes, which are vital for turbocharged engine components. Nano-layered coatings, such as TiAlN and AlTiN, offer improved thermal stability and resistance to oxidation, crucial for high-temperature applications. Recognising that each turbocharged engine component may have unique machining requirements, ISCAR offers customised solutions (Figure 3). ISCAR’s engineering teams collaborate closely with clients to develop tools and machining strategies tailored to specific needs, ensuring optimal results and efficiency. This approach allows for the integration of advanced tool paths and machining parameters, maximising performance. ISCAR is at the forefront of digital transformation in manufacturing. The company’s innovative tools and digital solutions enable real-time monitoring and data analysis, allowing manufacturers to optimize machining processes, reduce downtime, and increase overall efficiency. By integrating Industry 4.0 technologies, such as IoT-enabled tool management systems and predictive maintenance platforms, ISCAR helps clients stay competitive in a rapidly evolving market. Choosing ISCAR’s solutions for machining automotive turbo engines provides several key advantages. Firstly, with innovative tools and technologies, machining processes become faster and more efficient, reducing cycle times and increasing productivity. Longer tool life and improved machining performance lead to lower overall manufacturing costs, providing significant economic benefits. Additionally, ISCAR’s solutions ensure high-quality finishes and precise machining, essential for the demanding specifications of turbo engine components. Efficient machining practices result in less waste and reduced energy consumption, contributing to more sustainable manufacturing processes. In the competitive automotive industry, ISCAR stands out as a key partner, offering cutting-edge solutions for machining turbo engines. By addressing the unique challenges of machining advanced materials and complex geometries, ISCAR not only meets the industry’s current demands but also paves the way for future advancements. With a commitment to quality, efficiency, and innovation, ISCAR continues to drive the machining industry forward, helping manufacturers achieve new levels of performance and success. /episode/index/show/mtdmag/id/38154960

Brother’s blue technology revolution: How energy efficiency is transforming UK manufacturing economics 09/10/2025

Brother’s blue technology revolution: How energy efficiency is transforming UK manufacturing economics The manufacturing landscape is shifting as energy costs and environmental responsibility become as important as speed and quality. Brother’s Blue Technology leads this change, optimising machine design to minimise waste in time, resources, energy, and space. Peter Smith of Whitehouse Machine Tools, Brother’s UK distributor, says it marks a paradigm shift in machine tool investment evaluation. MTDCNC spoke to Peter to find out more… Do your machine tools reduce energy consumption—benefitting manufacturers’ bottom line and the environment? “The Speedio series of machining centres from Brother certainly do. They use patented motor technology to capture and redeploy power, and they use less air, a dual benefit of Brother’s Blue Technology approach.” The Blue Technology Philosophy: Eliminating Manufacturing Waste Brother’s Blue Technology eliminates waste throughout manufacturing, focusing on efficiency across the entire machine cycle. It emphasises the importance of how efficiently a machine produces, recognising modern competitiveness depends on this. The foundation of Blue Technology lies in Brother’s ‘low-mass, high acceleration’ design philosophy, which Smith describes as fundamental to achieving superior efficiency. “The machines use Sanyo Denki drives—the world’s fastest reacting servo motors. They have a very special design with IPM interior permanent magnet technology that essentially harness energy like you would get from an F1 car. It’s beautiful, really, the way that it works. So the acceleration and deceleration characteristics of the machine mean that the motors are creating lots of energy, but then they can harness that energy and redistribute it back into the machine.” This energy regeneration technology marks a breakthrough in machine tool efficiency. During typical machining processes, the electrical energy produced during spindle and axis deceleration is usually converted into heat and lost. Brother’s IPM (Interior Permanent Magnet) servo motors recover this energy and redirect it back into the machine system to establish a regenerative cycle Real-World Energy Performance: The 80% Reduction Achievement Smith’s most compelling evidence for Blue Technology’s effectiveness comes from extensive real-world field testing conducted with wireless energy and air monitoring equipment measuring actual consumption. “Using the wireless monitoring technology on a customers 40 taper 5 axes, we’ve run the same program/parameters on a Brother, 5-axes. Running the same parts on both machines, the Brother actually achieved almost 90% energy saving.” This extraordinary 90% energy reduction translates into substantial financial benefits. Smith calculates the economic impact with precision: “If you take an average energy tariff in the UK, the Brother over the other machine doing the same job saves between £5,500 to £6,000 per shift per year. So, if we’re operating a double shift, over a year, electricity savings will be £11,000 to £12,000. Over a five-year period, which is generally how people finance machines, manufacturers will save £55,000+.” “These savings compound across multiple machines. For manufacturers operating five machines on double shifts, the annual energy savings rise to £275,000 over a typical five-year financing period. In an era of volatile energy prices, these reductions provide both immediate cost benefits and long-term economic stability.” Brother’s own documentation supports this data, with official testing demonstrating 80% energy reductions in a variety of cutting applications compared to typical BT40 spindle machines. This performance stems from multiple on machine technological innovations working in collaboration, rather than any single efficiency improvement. The Four Pillars of Blue Technology Efficiency Brother’s Blue Technology reduces waste in four areas, improving efficiency. The first focuses on eliminating time waste with high-acceleration / deceleration servo systems, optimised dynamics and rapid tool change times (0.7 seconds). Smith notes: “It’s not about the rapid rate. It’s about acceleration rates. Most machining centres operate around 0.6 to 0.8G axes acceleration, Brother Speedio’ are much faster at up to 2.2G.” These performance characteristics deliver healthy cycle time reductions, between 20% and 70% depending on the application, compared to 40 taper technologies. The second pillar targets resource waste through efficient coolant systems, LED lighting, and reduced compressed air consumption. Brother’s mechanical tool change system exemplifies this approach, requiring minimal pneumatic assistance compared to traditional alternatives. “The whole tool change is mechanical using a linear cam mechanism. Air is only used briefly to clean the spindle taper. That’s a huge saving when you look at air consumption,” Smith notes. Energy waste elimination forms the third pillar, incorporating IPM servo motor technology, energy regeneration systems, and optimised control algorithms. The fourth pillar addresses space waste through compact machine designs that deliver equivalent or superior capability within significantly smaller footprints. Advanced Motor Technology: The Heart of Energy Efficiency Brother’s energy efficiency is founded on IPM motor technology. Smith states: “IPM interior permanent magnet servos respond quickly to rotation and stop, enabling efficient cutting with less power. Unlike normal induction motors, it starts instantly and efficiently.” IPM motors incorporate permanent magnets embedded within the rotor, providing superior efficiency and responsiveness compared to induction alternatives. This design enables rapid acceleration and deceleration whilst minimising energy waste during speed transitions. The energy regeneration capability represents perhaps the most innovative aspect of Brother’s motor technology. During deceleration cycles, the IPM motors function as generators, converting kinetic energy back into electrical energy. This recovered power is redistributed throughout the machine system, reducing overall grid consumption. The technology effectively transforms what was previously waste heat into useful energy, creating a regenerative cycle that compounds efficiency gains throughout extended operation periods. Brother’s dedication to motor efficiency covers all machine axes. The Sanyo Denki servo drives for the linear axes offer quick response, ensuring energy efficiency benefits both positioning and cutting. Control System Integration Brother’s D00 control system plays a crucial role in Blue Technology implementation, incorporating specific features designed to minimise energy waste during non-productive periods. Smith highlights the system’s comprehensive approach: “A variety of functions such as auto coolant off, auto machine lights off, and auto power-off are installed to ensure power saving.” The control system’s 1000-block look-ahead, sub-micron control capability enables optimised toolpath execution that minimises unnecessary acceleration and deceleration cycles. By analysing upcoming machining operations, the system can optimise spindle speeds and feed rates to maintain efficiency. The D00 control incorporates an energy monitoring application that enables real-time visualisation of power consumption, helping operators identify opportunities for further efficiency improvements. This transparency allows manufacturers to understand exactly how their machining strategies impact energy costs. Compressed Air Efficiency: The Often-Overlooked Savings While electrical energy consumption receives primary attention, compressed air efficiency represents another significant cost reduction opportunity. Smith emphasises this often-overlooked benefit: “It doesn’t use a great deal of it, but the bit that it does use is obviously critical.” Brother’s mechanical tool change system exemplifies the compressed air efficiency approach. Unlike traditional tool changing systems that require significant air consumption for each operation, Brother’s mechanical system requires only minimal air for chip clearing. The mechanical approach reduces air use during tool changes. While conventional systems need compressed air to stop the spindle quickly, Brother’s system keeps it moving, eliminating this energy waste. For manufacturers operating multiple machines, compressed air savings can represent thousands of pounds annually. The efficiency gains also reduce compressor sizing requirements for new installations, providing capital cost savings beyond operational benefits. The Hidden Economics The total cost of ownership analysis shows advantages of Blue Technology adoption. Beyond energy savings, manufacturers see reduced maintenance. The mechanical tool change system wears less than pneumatic options, and IPM motors’ efficiency decreases heat and bearing stress. Factory costs compound the economic benefits of Brother’s compact designs. Smith calculates that Brother machines typically require 25 to 30% less floor space than equivalent BT40 systems. In high-value manufacturing, this can save thousands. The reliability benefits further enhance the total cost of ownership (TCO). “Brother machines are built for lights-out three-shift running. So our advice is run them flat out.” Environmental Responsibility Brother’s Blue Technology addresses rising corporate environmental standards by reducing CO2, supporting sustainability goals, and offering cost savings. Smith recognises the growing importance of environmental performance: “Companies’ efforts to promote energy saving bring a variety of values for their business operations. Amid global calls for carbon neutrality, promoting energy saving and contributing to decarbonisation will lead to an increase in corporate value.” For manufacturers pursuing environmental certifications or carbon trading schemes, the measurable efficiency improvements provided by Blue Technology offer valuable documentation. Overcoming Traditional Thinking Despite the compelling economic and environmental benefits, Smith acknowledges market perception of BBT30 Blue Technology, due to historical misconceptions and early adoption of 40 taper technologies, needs to be more open minded. “Engineers typically operate on personal experience or that or their peers and the UK market was an early adopter of 40 taper technology from manufacturers like Bridgeport & Cincinnati. Brother BBT30 Blue Technology has advanced so far in the last decade in efficiency and cutting capability, 40 taper users who have become uncompetitive now have the opportunity to regain a competitive edge with Brother” Smith continues: “We get too carried away with brand loyalty. Not one machine tool manufacturer has all the answers, furthermore buyers become fixated on a deal rather than TCO. WMT CNC & Brother are developing a method of predicting TCO for machine investments so buyers can take a long-term investment decision at the point of purchase. The journey to market transformation requires manufacturers to assess machine tool investments through thorough economic analysis rather than relying on past preferences. Smith’s approach stresses empirical testing: “Supply us with your ISO programme. We’ll run it, and we’ll give you our honest opinion about whether a BBT30 taper Brother could improve the ROI.” /episode/index/show/mtdmag/id/38154945

Advanced digital manufacturing with AI-powered solutions 09/09/2025

Advanced digital manufacturing with AI-powered solutions In July, we discussed our visit to the Hexagon event at Mills CNC, where Hexagon’s Nexus platform was shown. The event also alluded to how Pro Plan AI demonstrated 70 to 75% programming productivity improvements. With such impressive statistics and other products on show, we wanted to dig a little deeper into the production intelligence solutions. By Rhys Williams Real-Time Production Intelligence with Datanomics Zoltan Tomoga, Product Manager for Hexagon’s Production Software Business Unit, detailed Datanomics’ comprehensive approach to production monitoring, emphasising its zero-operator-input design that sets it apart from competing solutions. “Most machine monitoring solutions require the operator to tell the solution why the machine is stuck. The problem is, if you’ve got a big list of reasons, operators will often select the first one, always a broken tool, as opposed to the coolant or whatever. Whereas Datanomics is completely no operator input.” The system’s connectivity architecture enables comprehensive data collection without disrupting workflow. “Each machine has an Ethernet port that will connect to a network, and then you can pull information off of it, as well as push information to it. With our CAM software, we typically push the program through the Ethernet,” Zoltan noted. Datanomics serves three distinct user categories with targeted interfaces designed for specific operational needs. For management, ‘you are mainly interested in OEE. You want to see how much of your shop is utilised.’ The primary focus targets shop floor managers who require intelligence: “Every morning at six, we send out the coffee cup report, so when they arrive, the night shift is still there. They can open a report, see what’s happened and talk to relevant operators.” The Factory Mate AI enhancement offers instant problem diagnosis capabilities, enabling immediate corrective action. “A shop floor manager just arrived at the factory. There was one machine which didn’t perform very well. They hit the factory mate icon, and it will give them the top three downtime events. In this case, we were waiting for an operator. That was the second one as well, and the machine was stuck,” Zoltan demonstrated. For process engineers requiring deeper analysis, Datanomics offers comprehensive historical data capabilities that facilitate continuous improvement initiatives. “In EdgeCAM, if I generate an NC code, I can put what EdgeCAM says is going to be the cycle time. However, if the feed override, or the rapid wasn’t set to 100%, it might start to differ. The target for one part was 56 minutes, but we are actually running on 59 minutes recently. However, Datanomics thinks we could run that part in 45 minutes and improve on efficiency,” Zoltan explained, demonstrating how the system identifies specific optimisation opportunities. Tooling insights provide strategic procurement intelligence. “You will see which tool you use the most, and make a decision if you want to adjust speeds and feeds on that tool.” Benchmarking Progress: Quantifying Industry Digital Maturity The benchmarking initiative previously discussed in MTD May Issue with Jason Walker, Hexagon’s VP of General Manufacturing, has collected substantial industry data over twelve months, revealing concerning gaps in digital adoption across manufacturing operations. The results confirmed extensive manual processes that create competitive disadvantages. “More than half of manufacturers are still using a manual process, which typically involves whiteboards and Excel spreadsheets and a lot of manual planning,” Walker revealed. Most of the upstream processes for winning work, like quoting and planning, are very much done manually.” Production intelligence gaps create significant profitability challenges for manufacturers who are unable to track actual versus planned performance. “Understanding the utilisation of the machines on the shop floor probably comes all the way back to the quoting process and understanding the profitability of your business, because if you’re quoting that a part is going to take two hours to machine, and you have no traceability to see who did that part or whether that batch of 1000 parts did actually take two hours each. Or did they run at two hours and five minutes, which makes a large difference over the batch,” Walker explained. The competitive implications of slow processes are significant for business sustainability. “Ultimately, many of these companies, when they are winning the work, it’s because they’ve under-quoted on a job which further erodes their profitability,” Walker observed. External pressures are accelerating transformation requirements. “Lockheed Martin has a model-based enterprise playbook for suppliers. Lockheed are actively saying to their supply chain, if you aren’t going to adopt these new technologies that are going to allow you to manage the digital thread through the digital models that we’re going to provide you with, then ultimately, you will be losing out on work in the future,” Walker shared, demonstrating how OEMs are making digital transformation mandatory. Quantifying Digital Transformation Benefits The event demonstrated how digital manufacturing solutions deliver measurable business improvements across multiple operational areas that justify investment through concrete returns. The integration of solutions presented in Part One—Nexus connectivity, Pro Plan AI programming acceleration, and Paperless Parts quoting automation—creates compounded benefits when combined with real-time production intelligence from Datanomics. Pro Plan AI’s 70 to 75% reduction in programming time enables manufacturers to complete days of work in mere minutes while capturing institutional knowledge from experienced programmers. This capability, combined with Mills CNC’s DNX 2100 launch aimed at reducing setup time, exemplifies an industry-wide shift towards efficiency optimisation. Paperless Parts transforms quote-to-cash cycles from week-long manual processes into 24 to 48 hour automated workflows, enabling customers to secure 25% more business through quicker response times. The platform removes resource constraints by alleviating quoting burdens from owners and managers. Datanomics provides real-time production intelligence without requiring operator input. This enables shop floor managers to identify and resolve issues through immediate problem diagnosis and historical trend analysis. The system’s ability to compare target and actual cycle times reveals optimisation opportunities, such as identifying potential efficiency improvements. The benchmarking data reveals that over half of manufacturers still rely on manual processes for critical business functions. Looking Forward: Measuring Manufacturing’s Digital Future The convergence of AI-driven programming, automated quoting systems, and real-time production intelligence generates combined benefits that surpass the capabilities of individual solutions. Manufacturers adopting comprehensive digital workflows can realise simultaneous enhancements in quote win rates, programming productivity, and production efficiency while tackling workforce challenges through knowledge capture and skills augmentation. Hexagon’s platform approach allows manufacturers to implement digital transformation incrementally, measuring benefits at each stage while working towards comprehensive integration. The partnership with Mills CNC illustrates how technology providers and equipment manufacturers can collaborate to achieve measurable business outcomes that justify digital investment through quantifiable improvements in productivity and profitability. Concrete business metrics will measure success in this digital transformation: quicker quote turnaround, higher win rates, reduced programming time, improved production efficiency, and enhanced workforce productivity. Manufacturers achieving these measurable improvements—through solutions like those demonstrated at the Mills CNC Technology Campus—will define the competitive landscape for the next decade of industrial production. Meanwhile, those failing to adapt risk losing business to more digitally capable competitors as customer requirements continue to evolve towards integrated digita /episode/index/show/mtdmag/id/38140040

Life on the ocean wave 09/09/2025

Life on the ocean wave For nearly forty years, Pendennis Shipyard has established itself as a global leader in building, refitting, and restoring fully bespoke superyachts from its 14-acre waterfront site in Falmouth, Cornwall. The esteemed shipyard employs over 550 skilled craftspeople across various trades, including machining, fabrication, electrical work, and joinery, all working within cutting-edge facilities that feature a 150m dry dock, two 90m construction halls, and an enclosed non-tidal wet basin. The company’s machining operations have been consolidated into The Digital Manufacturing Centre (DMC), a facility capable of producing everything from 2mm diameter pins to components for 8m booms. This centralisation has enhanced their capabilities, with Workshop Manager Jack Chuter now able to efficiently coordinate both replacement parts for existing vessels, which account for 60% of the centre’s work, and collaborate with surveyors and designers on new components that must be both functional and aesthetically pleasing. Pendennis started their CNC journey in 2015 with an XYZ SMX 4000 bed mill, chosen specifically for its conversational programming capabilities while keeping manual operation options. “We didn’t want to jump straight into full CNC machining,” explains Jack. “The SMX 4000, with its conversational programming and manual capability retention at a great price point, was perfect for developing the workshop.” This strategic approach proved successful, immediately enhancing both efficiency and accuracy while broadening the scope of parts that could be manufactured. The success of this initial investment led to the purchase of a ProTURN SLX 555 x 1m CNC lathe the following year. However, as demand for superyacht refits continued to grow, Pendennis recognised the need for more advanced machinery to meet increasingly difficult requirements, including tighter deadlines and more demanding materials. Recent additions include the XYZ 1100 HD vertical machining centre and XYZ TC 400 slant bed turning centre, investments driven by evolving industry demands. “We needed machinery that could tackle everything from aluminium and phosphor bronze through to 316 stainless, 17-4 Duplex and Nitronic 50-60 with ease,” notes Jack. “Reducing cycle times was important, but equally crucial was developing multi-tasking capabilities by running machines unattended during production.” The XYZ 1100HD, with travels of 1.1m by 610 by 610mm in X, Y, and Z axes, proves ideal for machining tough, sea-resistant materials. Its hardened box section slideway construction and BT40 spindle taper, combined with a 21kW spindle motor delivering 5-10,000 rpm, provide the power and versatility needed for superyacht applications. Similarly, the XYZ TC400’s 400mm maximum turning diameter, 600mm turning length, and 78mm bar capacity provide flexibility for both single components and larger batches. Its 32kW spindle motor, which delivers a maximum of 3300 rpm, has already proven invaluable for the workshop’s expanding needs. The DMC employs three highly skilled machinists alongside apprentices who benefit from Pendennis’s award-winning training scheme. This mix of manual XYZ lathes for simple work and apprentice training, Prototrak-controlled machines for one-off and simpler parts, and Siemens-controlled equipment for complex, high-volume work creates an ideal learning environment. Programming combines CAD-CAM for 90% of milling tasks with conversational software for turning operations. Investment in XYZ machinery, alongside CNC waterjet and 5-axis router equipment, has not only enhanced in-house capabilities but increased the shipyard’s appeal to young talent. With nearly a third of the workforce having completed apprenticeships at Pendennis, growing their own expertise remains integral to success. /episode/index/show/mtdmag/id/38140035

Empowering growth with cutting-edge machinery 07/17/2025

Empowering growth with cutting-edge machinery NDT Equipment Limited, a valued customer of Close Brothers Asset Finance, has secured finance to upgrade its machinery and handle an increasing workload. Customer background Founded in early 2022 by Daniel Lenton and Katie Loydall, NDT Equipment Limited specialises in manufacturing fully traceable ultrasonic calibration blocks. These blocks ensure the accuracy and reliability of ultrasonic flaw detection equipment and are essential for identifying flaws in metals, composites, and other engineering materials. They serve a wide range of industries, including oil and gas, nuclear, aerospace, automotive, and general sales, both in the UK and international markets. Over the past three years, the business has expanded to offer subcontract work alongside its engineering products. Providing innovative machinery When the company was in its early stages, Dan bought Doosan and XYZ CNC machines for manufacturing. However, after rapid growth, Dan required a new machine to further enhance their capabilities, resulting in an order (while attending MACH 2024) for a new Matsuura MX-330 PC10 multi pallet, 5-axis, vertical machining centre. The machine now means NDT can offer bespoke innovative solutions and manufacture anything from prototypes to medium and large batch work. Oliver Shaw, Area Sales Manager at Finance for Industry, has worked closely with Daniel and Katie since they started the business, and created a bespoke Hire Purchase deal that meant NDT could access the new machinery without upfront costs. The finance solution breaks the cost into manageable monthly payments, supporting the company’s continued growth. Result: This deal marks a significant milestone in NDT’s journey, positioning them at the forefront of innovative engineering solutions. Oliver Shaw, Area Sales Manager, said: “It’s always a pleasure working with Daniel and Katie. Watching the growth of their business from the start, I’m excited to see what’s next for them, and we are cheering from the sidelines!” Daniel Lenton, Co-Owner of NDT Equipment Ltd, added: “We’re delighted with this deal. Access to this type of machinery puts us at the forefront of the industry and allows us to provide innovative solutions that go beyond traditional tooling and work holding.” Products and services are subject to eligibility, status, terms and conditions and availability. All lending is subject to status and our lending criteria. The right to decline any application is reserved. For more information please visit: closeassetfinance.co.uk/s/ggs /episode/index/show/mtdmag/id/37442030

Paris mood reflects defence sector spending spree 07/17/2025

Paris mood reflects defence sector spending spree With civil aerospace primes targeting production rates of 75 per month by 2027, and NATO members increasing defence spending to over 2.5% of GDP, business is brisk in the aircraft and defence sectors. The Paris Air Show in June showcased several UK companies that are investing during strong business conditions, says Will Stirling. Bathed in blazing sunshine, Paris Le Bourget Airport hosted the 55th Paris International Air Show from 16 to 22 June. A large UK pavilion featuring over 50 exhibitors joined thousands more. Aerospace is on the rise – the aerospace, defence, security, and space sectors contributed £42.2bn to the UK economy last year, marking a 10.4% increase from 2023. Defence is also poised for significant growth: Britain’s defence spending will increase to 2.5% of GDP by 2027, up from approximately 2.3% in 2024, representing an additional £6bn per year. Furthermore, the government aims to elevate spending to 3% of GDP, potentially adding a staggering £20bn annually on top of the 2.5% baseline by 2030. A large fraction – likely over £20bn annually by 2030 – will be allocated specifically to equipment and weapons programmes such as missiles, submarines, nuclear infrastructure, drones, tanks, and factory expansion. ADS, the aerospace, defence and security industries business group, hosted nearly 100 companies at this year’s Paris Air Show, predominantly manufacturing firms that produce everything from machined components, roll forming and composite structures to avionics and AI-powered digital engineering. MTD examines some of the exhibitors’ news. Faster composite production for wing tips iCOMAT is a Gloucester-based advanced manufacturing company that has developed an automated composite production process, the Rapid Tow Shearing (RTS) process. Working for aerospace primes and defence customers, the RTS, which enables defect-free fibre steering for composites, is helping to advance new lightweight, high-performance structures. The company is one of several innovative SMEs working with GKN Aerospace on a new £12m R&D programme to develop and demonstrate next-generation composite wing and flap structures, called ASPIRE – Advanced Structural Product Integrated Airframe. The project will deliver three full-scale composite wingtip variants for structural testing to ultimate load, allowing the consortium to validate new technologies in highly relevant test conditions. Each wingtip variant will represent a different structural philosophy and technology set. Variant one is a bonded assembly with multiple parts, aligned with GKN Aerospace’s design approach. It will validate the manufacture of three wingtip variants. The ASPIRE consortium includes Carbon ThreeSixty, iCOMAT, Lineat, Pentaxia, and the University of Bath, with support from agency Axillium and co-funding from the Aerospace Technology Institute. ASPIRE will also develop an optimised composite flap. The flap demonstration will feature a pre-preg manufacturing approach with RTS skins provided by iCOMAT, tailored fibre-placed brackets from Carbon ThreeSixty, low-energy out-of-autoclave curing moulds, and press-cured ribs. A key programme milestone will be achieving TRL6, Technology Readiness Level 6, for the press-curing of composite ribs. “ASPIRE is a perfect example of the power of UK collaboration to drive aerospace innovation,” said John Pritchard, president for civil airframe at GKN Aerospace. “By bringing together specialist SMEs, academic expertise, and GKN Aerospace’s industrial leadership, this programme will accelerate the development of high-rate, sustainable composite wing technologies.” Martin Baker For nearly 80 years, Martin Baker has designed, manufactured and fine-tuned ejector seats in the UK in Denham, Middlesex, and at locations globally. In that time, these devices have saved more than 7,700 aircrew members’ lives from over 90 air forces. The seats are fitted to programmes including the F-35 Lightning II, Eurofighter Typhoon, F-16 (some versions) and BAE Systems Hawk. At Paris, the company showcased the flagship US16E ejection seat. The Lockheed Martin F-35 Lightning II aircraft is the company’s biggest programme, and the US16E seat equips all variants of the F-35. More than 1,500 US16E seats have been delivered for 12 international F-35 operators; the US16E has saved the lives of 10 aircrew to date. The US16E seat became the genesis for the new Mk18 ejection seat range, with improved ejection performance, reducing the risk of ejection and minimising life cycle costs. The new technology has allowed safe ejection for aircrew with nude weights as low as 46.7Kg (103lbs) and ejection up to speeds as high as 600Kts for aircrew wearing Helmet Mounted Displays, a common peripheral in modern combat operations. Martin-Baker is offering the Mk18 seat range to all the new aircraft trainer and fighter aircraft programmes. The company has doubled its headcount in the last 10 years, and 28 apprentices are enrolled across the business. Complex aerospace systems need AI As aviation becomes more deeply sophisticated and data-reliant, data analytics companies must coordinate. Aerospace engineering companies are prolific users of simulation software to test component performance in different scenarios. AI (artificial intelligence) means you can explore designs 1,000x faster than physics-based simulation, according to Altair Engineering, which was acquired by Siemens in March. In Paris, Altair demonstrated how its solutions are helping the aerospace sector from concept through production to in-flight performance. It applies AI to combine several powerful technologies: digital engineering, smart factories, certification by analysis, digital maintenance, repair and overhaul, and digital twins. “AI, data, and connectivity are no longer future concepts — they are today’s competitive advantages,” said Dr. Pietro Cervellera, senior vice president of aerospace and defence, Altair. “Our technologies are helping the aerospace industry achieve next-level performance, sustainability, and innovation breakthroughs.” Demonstrations showed how engineers can reduce design cycles, optimize structures for weight and strength, and improve aircraft performance using intelligent, AI-assisted modelling tools. Beyond the marketing, however, the use of AI in simulation has an essential role in democratising engineering. These solutions empower government agencies and startups to deliver advanced programmes quickly. The Altair Aerospace Startup Acceleration Program gives young companies enterprise-grade tools to bring novel technologies to market faster. Altair has recently partnered with the Campania Aerospace District in Italy to provide over 150 SMEs and startups with access to AI simulation tools, empowering them to work at the same technological level as OEMs and tier-one suppliers. Rocket science inspires students to manufacture The continued growth of the aerospace, defence, and security sectors requires a skilled talent pipeline. ADS also supports Race2Space, a multi-university and company initiative that engages young people in designing and building rockets and space systems. Announced at Paris, Carrie Waters, 18, a first-year physics student at Durham University, has spent the past year helping to build a powerful, 600kg thrust liquid-fuel rocket engine. She is a member of Durham University Spaceflight, a student-run rocket launching team competing in this year’s Race2Space. In July, the team will ‘hot fire’ their engine at the Westcott Space Cluster during the final stage of the competition. In this crucial test, the engine will be securely mounted and ignited horizontally while connected to pressurised fuel systems. The engine must demonstrate its ability to perform under extreme conditions—delivering the correct thrust, flow rates, and structural integrity—before being launched as part of a future rocket. It’s like Heinz Wolff’s The Great Egg Race on Rocket Fuel. “I’m really excited, I’ve never done anything like this before,” said Carrie. “I can’t wait to see whether what we’ve designed and built actually works. It’s very daunting. I’ve had a great time working with the team and learnt so much.” Carrie believes that initiatives like Race2Space are vital for helping students from all backgrounds turn academic learning into career opportunities. She hopes to one day work for organisations like Skyrora or the European Space Agency, contributing to rocket and satellite missions. /episode/index/show/mtdmag/id/37441980

Innovating for aerospace manufacturing 07/17/2025

Innovating for aerospace manufacturing The aerospace industry stands at the intersection of extreme technological demands and cost-efficiency requirements. With aircraft manufacturers like Airbus and Boeing projecting the production of 42,500 new jets over the next 20 years, the need for precision machine tools and cutting tools has never been more critical. Aircraft construction is an intricate process that involves a complex array of materials, each presenting unique machining challenges. Aluminium alloys dominate the industry, comprising approximately 60% of aircraft components, while titanium and advanced composites play critical roles in structural and performance-critical areas. Aluminium alloys, particularly from the 2xxx, 6xxx, and 7xxx series, offer an ideal combination of lightweight properties and structural integrity. These materials require sophisticated machining approaches that balance material removal, surface quality, and dimensional precision. High-speed cutting (HSC) technologies have emerged as a vital solution, enabling manufacturers to address the demanding requirements of aerospace component production. It is in this area that Walter is innovating with its cutting tool solutions. Aircraft construction involves a complex array of materials, each presenting unique machining challenges. As aluminium alloys comprise approximately 60% of aircraft components and require sophisticated machining approaches, Walter’s high-speed cutting (HSC) tools, such as the M2131 and M2331 milling cutters address the specific challenges the industry faces with these materials. The two insert sizes allow for depths of cut of 15 to 20mm, achieving chip removal rates of up to 11 litres per minute. Both milling cutters work almost seamlessly when repositioned, resulting in smooth surfaces even during pre-finishing. The dense, smooth PVD coating of the cutting edges makes them extremely stable and also ensures that there is hardly any cutting edge build-up. The creative design of the insert seat secures the insert against the high centrifugal forces that occur during high-speed cutting. At the same time, internal cooling channels deliver the coolant directly to the cutting edge to extend tool life and ensure exceptional chip evacuation. Titanium Alloys: Conquering Difficult Machining While aluminium alloys are used for fuselages and wings, titanium alloys, such as TiAl6V4 or Ti5553, are employed where an exceptionally high degree of rigidity is required, such as in landing gear components, struts, or flap tracks. The hardness and low thermal conductivity of titanium necessitate high requirements for the cutting tools, particularly regarding process reliability. Rapid cutting edge wear and low cutting parameters make machining titanium parts very time-consuming. Companies that succeed in reducing the machining time per component maintain a clear competitive advantage. Here, the Walter BLAXX M3255 helical milling cutter provides breakthrough solutions. The innovative geometry of both the milling body and the indexable inserts ensures that the maximum number of teeth can engage with the material, while the soft-cutting insert geometry results in positive cutting behaviour that consequently reduces machining times and offers higher metal removal rates. Heat management poses challenges when machining titanium alloys due to their low thermal conductivity; therefore, an optimised coolant supply to the cutting edge is essential. The Walter BLAXX M3255 is designed to create excellent chip clearance space that guarantees reliable chip removal, even at high cutting rates. The tangential positioning of the two or four cutting-edged indexable inserts allows for maximum cutting power and enables the machining of forged components, where the peripheral zone of the forged skin presents extreme challenges for the tool’s edge. Ideal for rough machining applications, the Walter BLAXX M3255 helical milling cutter reduces titanium machining time by approximately 22% and extends tool life by around 100% through its innovative insert geometry and optimised chip clearance, which maximises material engagement and removal. Superalloys: Ceramic Cutting Technology Correlating with the well-filled order books is the requirement placed upon engine manufacturers and the supply chain for machining heat-resistant superalloys (HRSA). Here, too, shorter machining times are highly desirable. The cutting speed of carbide milling cutters on HRSA materials is typically around 50m/min. However, ceramic cutting tools push the boundaries with cutting speeds of up to 1000m/min, a 20 times improvement. The SiAlON ceramics offer excellent possibilities for this, as they are less sensitive to temperature fluctuations than whisker-reinforced ceramics, making them the first choice for milling operations in HRSA. The interrupted cutting during milling causes the temperature at one cutting edge to vary, and the use of coolant can further increase the temperature difference. In the worst-case scenario, the so-called ‘thermal shock effect’ occurs, leading to cracks and even fractures. Dry machining is therefore recommended when machining superalloys with ceramic milling cutters. A positive side effect is that the ecological footprint of the milling operation is improved because lubricants are not required. Blisks are classic components made of nickel-based alloys. These bladed disks are often rough machined using carbide milling cutters. However, the machining time for this can easily exceed 30 minutes with conventional milling cutters. A ceramic milling cutter with a high feed geometry can machine the same features in just ten minutes. Feed rates of up to 9500mm/min can be achieved in a heat-resistant nickel-based alloy with a hardness of 44HRc and a tensile strength of 1400N/mm²; such machining values would be expected in aluminium, not HRSA. For HRSA machining, Walter introduces revolutionary ceramic milling solutions such as its MC075 high-feed geometry end mills. Available in a range of options including screw-in ConeFit interfaces, the MC075 ceramic end mills can deliver cutting speeds of up to 1000m/min utilising advanced SiAlON ceramic technology for superior temperature resistance. Future-Forward Strategies: Near-Net-Shape Unlike the automotive industry, where mass production dominates, the quantities required in the aerospace industry are comparably small, with the largest manufacturers like Airbus only producing around 750 aircraft a year. This makes ‘tool-free’ production of components using 3D printing a feasible alternative, especially as the process enables the production of complex and stable components. Furthermore, it reduces the weight of conventionally manufactured components by up to 55%. This subsequently reduces the consumption of raw materials by up to 90%. From a machining perspective, there are also developments in this area that significantly optimise component production in terms of technology and costs. Fuselage sections, wings, tail units, engine components, and other complex assemblies are now being forged or 3D printed as close as possible to their ‘Near Net Shape’. It means significantly less material has to be removed. This not only saves material and machining time but also reduces waste - and thus enables more efficient manufacturing. Technological Integration The question of whether machine tools will still be needed in the future could well be asked in view of developments such as 3D printing or contour-based manufacturing. The answer is a resounding yes! Almost all 3D-printed workpieces require subsequent machining because their surface quality is usually insufficient for the components to be fitted directly. This is caused in no small part by the so-called ‘staircase effect’ that occurs in the powder bed process typical of 3D printing. Heat treatment of steel components can also result in hardening distortion, which must be eliminated. Furthermore, support structures must be cleanly removed. All of these factors make cutting tools indispensable – now and in the future. The Economic Impact of Walter Solutions As an industry leader, Walter has proven the merits of its technical advances in the aerospace sector throughout the manufacturing supply chain. For the production of aluminium structural components, a major aerospace manufacturer implemented Walter’s M2131 milling system for producing aluminium wing ribs. The result was a material removal rate (MMR) increase from 5.8 to 11 litres per minute with a 46% decrease in total machining time. Furthermore, the groundbreaking tool geometries of the M2131 system improved tool life by 35%, resulting in a 28% reduction in cost per component. Similar improvements have been witnessed when machining titanium Ti5553 landing gear components. By adopting the high-feed Walter BLAXX M3255 system, end users have benefitted from cycle time reductions beyond 22% when rough machining. Tool life improvements that are double the performance compared to the previous solution have subsequently yielded an overall 31% reduction in tooling cost per component. The machining of superalloy engine components is a particularly challenging niche where Walter once again excels. When machining blisk components from Inconel 718 (44HRc), the Walter MC075 ceramic milling system has delivered a machining time reduction from 30 minutes to 10 minutes per blade pocket, tripling throughput with existing machine tools and achieving machining cost savings of 65% despite a higher tool investment. As the aerospace industry commits to CO2-neutral operations by 2050, Walter’s tooling solutions support this narrative of sustainability and efficiency, contributing significantly with innovations that reduce energy consumption, minimise coolant and lubricant usage, enable more efficient manufacturing processes and support lightweight component design. Conclusion Walter demonstrates that advanced tooling is not just about cutting metal—it’s about enabling the future of aerospace technology. By combining innovative materials expertise, cutting-edge tool design, and a commitment to efficiency, Walter is helping aircraft manufacturers push the boundaries of what’s possible. Walter continues to innovate in response to evolving aerospace requirements with digital integration tools such as its tool management systems that increasingly incorporate digital capabilities. This now reaches far beyond the cutting tool to incorporate comprehensive digital twins of tooling systems for unparalleled tool data management, AI-assisted cutting parameter recommendations, and predictive maintenance tools for monitoring and forecasting tool wear for optimal utilisation rates. Readers can and download a free copy of the complete aerospace whitepaper: ‘A balancing act between high technology and cost efficiency’ here: https://pages.walter-tools.com/en-download-whitepaper.html /episode/index/show/mtdmag/id/37441100

Machining with CBN and PCD inserts 07/17/2025

Machining with CBN and PCD inserts In the realm of modern manufacturing, precision and efficiency are paramount. ISCAR consistently pushes the boundaries of innovation with its Polycrystalline Diamond (PCD) and Cubic Boron Nitride (CBN) tools. These advanced materials are transforming how industries approach machining to provide significant advantages. PCD tools are renowned for their hardness and wear resistance, making them perfect for machining non-ferrous metals, composites, and abrasive materials. ISCAR’s PCD tools are designed to provide precision and superior surface finishes, essential in industries such as aerospace, automotive, and electronics. The benefits of ISCAR’s PCD tools include extended tool life, as PCD’s exceptional hardness ensures that tools retain their cutting edge for longer periods, thereby reducing the frequency of tool changes and minimising downtime. Furthermore, cutting speeds can be increased. With PCD tools, manufacturers can operate at higher cutting speeds, thereby improving productivity and reducing cycle times. ISCAR’s innovations in PCD tooling feature specialised geometries that improve chip control and heat dissipation, further optimising performance in demanding applications. ISCAR’s CBN tools represent another cornerstone of its cutting-edge solutions, specifically designed for machining hardened steels, cast iron, and superalloys. CBN ranks second only to diamonds in hardness, making it an ideal material for tools that must maintain their integrity under extreme conditions. An essential advantage of using CBN inserts is the ability to replace the slow and costly grinding operations of hardened parts. Turning with CBN inserts significantly lowers the cost per part compared to grinding. ISCAR recognises that customers are shifting their finishing processes from grinding to turning with CBN inserts, particularly in the automotive industry. In grinding operations, size tolerance specifications exceed the capabilities of turning, while surface finish requirements are excessively stringent for hard turning. In hard turning, the size tolerance specifications surpass the turning capabilities, showcasing a complex geometry that makes single-point turning more practical. This method features relatively high metal removal rates, dry machining, faster machine setup, and shorter cycle times, facilitating both inner and outer diameter machining on a single machine. CBN is chemically passive when used in ferrous materials. CBN is a synthetic material produced by a high-temperature and high-pressure process. The finished product consists of one carbide layer and one CBN layer. The combination of the two materials is called a cubic-boron-nitride (CBN) wafer. CBN was developed to compete with the finish-grinding process of hardened ferrous materials (45-68 HRC) for economical cutting of 80 to 250m/min. CBN is also used in cast iron machining applications, allowing for extremely high cutting speeds of more than 1000m/min. Cutting tools made from CBN sintered materials are produced by mixing CBN with ceramics as hard as diamonds. Together, these materials are sintered at extremely high pressures and temperatures. Due to its low affinity and high hardness, sintered CBN delivers enhanced cutting performance, particularly for high-speed machining. The key advantages of CBN tools are: Superior Hardness and Strength: CBN tools withstand high temperatures and maintain sharpness even when cutting hard materials. This is essential for industries like automotive and aerospace, where hard turning is standard. Improved Productivity: The durability of CBN tools allows for higher cutting speeds and feeds, translating to faster machining processes and increased throughput. Reduced Tool Wear: With exceptional thermal and chemical wear resistance, CBN tools last longer than conventional carbide tools, leading to long-term cost savings. ISCAR’s commitment to innovation is evident in the development of multi-tipped CBN inserts featuring enhanced edge preparation, ensuring optimal performance in the most challenging machining environments. ISCAR’s insert types are designated as: MT Type - Mini-Tipped Multi-Cornered/Single-Use Inserts. These single-use inserts are designed to enhance machining efficiency by fully utilising each cutting edge. With a smaller and more economical CBN tip, they significantly reduce costs by providing more cutting edges per insert. The multi-cornered design features a single piece of ISCAR-CBN mounted on every usable corner. Single-sided inserts utilise the top corners, while double-sided inserts make use of both the top and bottom corners. Available in various shapes, square and diamond-shaped inserts, known as ‘Quadro’, offer 4 corners, whereas triangular inserts, referred to as ‘triple’, provide 3 corners. MM, MF, MR Chipbreakers Type CBN Inserts: ISCAR offers a variety of MT chipbreaker geometries tailored to provide optimal solutions for each specific application, ensuring excellent chip control in hard machining. These chipbreakers effectively prevent long chips and possible workpiece damage, while maintaining a stable and reliable production process. The MF-type inserts are customised for fine to medium cutting, MM-type inserts are perfect for medium machining, and MR-type inserts are intended for roughing operations. L Full Edge Tipped Inserts: Designed for productivity, these full-edge tipped CBN inserts come in various shapes to suit different machining needs. Triangular-shaped inserts feature a full edge tipped with CBN, while square-shaped inserts offer right or left-hand full-edge tipped CBN options. These inserts provide increased stability, enhancing overall machining performance HS Type Half Solid CBN Inserts: These inserts feature a top layer of CBN with a carbide base, offering multiple cutting edges. The high hardness achieved through a special binder results in excellent wear resistance, impact resistance, thermal stability, and chemical stability, making them ideal for metal processing. They provide exceptional cost performance, saving 30 to 50% compared to carbide inserts. The solid material ensures high mechanical strength, making it a superior cutting tool material for extreme conditions. These inserts lower machining costs, require fewer tool changes, and are 5 to 10 times more efficient than carbide and ceramic inserts. Solid CBN inserts are versatile and can be used across diverse industries. They are particularly effective for cast iron and hardened steel workpieces, including automotive engine components, brake discs, brake drums, pulleys, cylinder blocks, cylinder liners, pumps, and cast-iron rolls. For hardened steel, they are suitable for industrial gears, wind power bearings, drive shafts, crushing hammer cylinders, and slurry pumps. S Type Full Solid CBN Inserts are designed for aggressive machining conditions, offering numerous advantages such as excellent wear resistance, impact resistance, thermal stability, and corrosion resistance. They provide strong thermal stability and are ideal for high-speed machining, particularly roughing. These inserts save 30 to 50% compared to carbide inserts while delivering superior surface quality, enabling turning instead of grinding. The solid material ensures a high degree of mechanical strength, making it a superior cutting tool material. /episode/index/show/mtdmag/id/37440995

CERATIZIT’s advanced milling solutions 07/17/2025

CERATIZIT’s advanced milling solutions The machining of advanced materials presents challenges that demand specialised tooling solutions. CERATIZIT has now developed two milling systems that meet the specific requirements of difficult-to-machine materials: the MonsterMill ISO-S for nickel-based alloys and titanium, and the MaxiMill S-Power for cast iron applications. A Monster That Conquers Nickel-Based Alloys The machining of nickel-based alloys such as Inconel, Hastelloy, and Waspaloy present significant challenges. CERATIZIT’s redesigned MonsterMill ISO-S range addresses these challenges through a carefully engineered carbide substrate, advanced coating, and optimised geometry. The geometry has been specifically adapted to minimise heat and the polished chip flutes work in conjunction with an optimised coating to reduce friction. The irregular cutting edge pitch, combined with a variable helix angle, effectively minimises vibration during operation. This design feature significantly enhances machining performance while helping to prevent catastrophic tool failure. Microgeometry plays a crucial role in the tool’s performance. The precision-engineered preparation of the cutting edge reduces cutting forces while stabilising the edges. The design takes into account regrindability from the outset, offering clear advantages in the reconditioning process. The DPX22S Dragonskin coating represents a significant technological advancement. Applied in 4 to 6 microns layers, the coating provides thermal stability through its specialised layered structure. Four-edge cutters come in two different lengths with diameters ranging from 3 to 20mm, available with both HA and HB shank configurations. Five-edge variants offer diameters from 3 to 16mm with similar shank options, while the new six-edge configuration covers diameters from 6 to 16mm with HA shanks. Corner radii options range from 0.2 to 5mm for the four and five-edge variants, with the six-edge version providing 0.2 to 2mm radii. Optimised Cast Iron Machining Cast iron also presents its own set of challenges. Here, the MaxiMill S-Power series addresses these issues through a high tooth count design utilising double-sided indexable inserts. The key innovation lies in the tool’s ability to support an optimal number of cutting edges. The 88-degree setting angle enables a high tooth count while preserving small chip spaces, accommodating 12 teeth on a 63mm diameter cutter. The double-sided indexable inserts boast eight actual cutting edges crafted from carefully selected substrates and finished with DRAGONSKIN coatings. This design maximises insert utilisation while ensuring consistent performance throughout the insert’s lifespan. The inserts are peripherally ground to achieve precise tolerances and a superior surface finish. Available in standard diameters ranging from 56 to 125mm, the MaxiMill S-Power accommodates maximum cutting depths of approximately 8mm while maintaining efficiency through its high tooth count. The system is optimised for GJS, GJV, and GJL cast iron grades, with recommended feed rates between 0.08 and 0.15mm. The indexable insert range includes ISO P/K classifications with M cutting edge geometry, offering corner radii of 0.4, 0.8, and 1.2mm to meet various application requirements. Grade options encompass CTPK220, CTCP230, and ceramic variants to suit specific material and operating conditions. While the MonsterMill ISO-S addresses the thermal and mechanical challenges of aerospace-grade superalloys, the MaxiMill S-Power tackles a completely different set of problems encountered in high-volume cast iron production. Where the MonsterMill ISO-S utilises advanced geometry and coating technology to withstand the extreme conditions of nickel-based alloy machining, the MaxiMill S-Power leverages mechanical design advantages to improve cast iron processing. /episode/index/show/mtdmag/id/37440960

Machining strategies for aerospace milling 07/17/2025

Machining strategies for aerospace milling Machining aerospace alloys presents challenges to tool performance. A comprehensive strategy is essential to achieve optimal performance while avoiding process-limiting issues. These alloys are ideal for high-stress components due to their strength and heat resistance. However, their poor machinability stems from high strength and low thermal conductivity. Effective strategies encompass optimising cutting parameters, utilising advanced tool materials and coatings, and employing efficient cooling and lubrication techniques. Implementing precise toolpaths and chip evacuation can significantly enhance performance. “The biggest issue when machining high-temp alloys is heat,” says Danny Davis, Senior Staff Engineer Solutions at Kennametal. “We need to take special care in managing the heat through correct speeds, coolants, coatings and substrates.” Where is the heat coming from? Heat generated during cutting does not dissipate easily into the workpiece or chips when compared to other materials. This forces the tool, and sometimes the part, to bear the thermal burden. Every machining operation is essentially a thermal system where electrical energy enters the spindle and converts into kinetic energy (tool rotation and movement) and heat (from plastic deformation). During chip formation, three distinct phases occur: Rubbing, involving pure friction Plowing or plastic deformation, where approximately 90% of energy becomes heat Shearing, where actual chip separation occurs but still generates significant heat “Thermal energy is the biggest factor damaging the cutting edge,” said Steve George, Senior Manager, Product Design Engineering at Kennametal. Ways to Manage Heat in High-Temp Alloys Use tools designed for efficient cutting by reducing specific cutting energy—the energy required to remove a unit volume of material. Tools like HARVI™ I or HARVI II reduce cutting energy through optimised geometries and coatings. Deploy advanced coatings such as Kennametal’s KCSM15A grade, engineered specifically for high-temp alloys. Its smoother, thinner layer retains a sharper cutting edge while enhanced abrasion resistance makes it ideal for aggressive nickel-based alloy conditions. Increase lubrication with high-pressure coolant systems or minimum quantity lubrication (MQL) to reduce thermal loads, particularly at high cutting speeds. Lubrication cools and separates contact surfaces, directly reducing energy converted to heat during rubbing and plowing stages. Use tools made of insulating materials like ceramics or certain coated carbides. Since high-temp alloys have poor thermal conductivity, heat stays near the tool. If the cutting tool conducts heat better than the workpiece, it absorbs more heat and wears faster. Minimise contact time during chip formation. Traditional milling involves constant contact, increasing heat due to extended machining time. Dynamic milling uses smaller radial engagement and keeps the cutter moving with less surface contact. Coolant and Lubrication Best Practices High-temp alloys require strategic coolant management: Water offers excellent heat transfer but poor lubrication. Combat abrasion with coolant rich in extreme pressure (EP) additives. Air aids chip evacuation when coolant isn’t viable. Neat oils provide superior lubrication but are reserved for extreme cases due to maintenance requirements. Placement matters as much as volume. Ensure coolant hits the cutting zone directly—poorly aimed nozzles waste coolant and leave tools vulnerable. Tools like the HARVI IV series offer through-tool coolant delivery. “Higher coolant concentrations help reduce abrasive wear and manage heat when machining high-temp alloys,” said Katie Myers, Product Manager Marketing at Kennametal. “High-pressure through-tool coolant ensures effective heat removal and chip evacuation, crucial for tool life and part quality.” Using Ceramic Tools in a Dry Environment Ceramic tools offer unique advantages when machining high-temp aerospace alloys. Their extreme temperature resistance makes them well-suited for dry cutting where traditional carbide tools struggle. “When we discuss ceramic tools, we’re almost always talking about dry cutting,” explained George. “You need careful setup because ceramic tools are much more sensitive to tool path and workpiece geometry.” Managing heat without coolant is key with ceramics. George noted, “Heat is obviously a big concern with high-temp alloys, but ceramic likes heat. We want to generate heat and eliminate it quickly.” George advised avoiding re-cutting and ensuring good chip evacuation to prevent premature wear or failure. He suggested specific motion strategies: “Step the walls of pockets. As you step down, move away from the wall with each pass. This keeps the tool away from the heat zone and helps prevent excessive burr formation.” Effective Approaches for Solid End Milling of Aerospace Components Pocketing Techniques and Methods of Entry: Many aerospace parts feature deep, complex pockets requiring proper entry strategy and cutter selection, especially in materials prone to work hardening and thermal stress. “Pocketing is one of the most common aerospace operations, but it can be tricky with high-temp alloys,” said George. Plunge entry works best for small pockets with limited space. HARVI I TE or HARVI II TE solid end mills plunge directly into material, offering high flexibility for tight spaces. Ensure cutting forces don’t exceed machine capabilities. Ramp entry suits deeper pockets and allows more aggressive cutting. Straight angle ramping can significantly reduce cycle times but requires machine rigidity to withstand higher forces. Helical interpolation provides the most stable and efficient pocketing strategy due to lighter depth of cuts. Corner geometry requires careful consideration. Oversized tools can cause excessive radial engagement in tight corners, increasing wear and chatter. “If you have a half-inch radius corner, use a three-quarter-inch diameter tool, maybe even 5/8,” said George. “Use a small enough tool to follow the corner arc without gouging or over-engagement.” Minimising Chatter and Maintaining Rigidity: Chatter often stems from machine-tool interface issues with high-temp alloys. Even the best tool can fail if the spindle or machine lacks rigidity to absorb cutting forces. “Chatter occurs when there’s too much movement between tool and part, leading to inconsistent cuts and tool wear,” explains Myers. “The best way to reduce chatter is ensuring your machine has sufficient rigidity.” If chatter persists despite adjusting stickout and tool selection, reduce depth of cut to lessen cutting forces instead of slowing feeds and speeds. This keeps vibrations in check without impacting cycle time. “Even with a robust machine, combining long stickout and weak spindle can lead to chatter. It’s about balancing tool size, rigidity and cutting force,” George says. Cutting Parameters and Tool Life Tool longevity directly relates to cutting parameters. Running tools at correct speeds, feeds and chip loads ensures maximum tool life while preventing premature wear. Speed is crucial when machining high-temp alloys—too fast burns through tools quickly. Chip thickness is equally important. Light radial engagement without proper feed compensation leads to rubbing rather than cutting, generating excess heat and accelerating wear. Wall Stiffness and Support Geometry When machining features like blisks, isogrids, or blades, geometry plays a critical role in maintaining part stability and minimising deflection. Adjacent or curved walls often reinforce features, offering opportunities to exceed standard roughing rules. “The curvature of the blade actually adds stiffness to that part,” said Davis. “These rules are guidelines. If the wall has curvature, adjacent walls, corners, or bottom radii—all add stiffness.” Conclusion Machining aerospace components from high-temp alloys demands more than just the right tools—it requires a comprehensive strategy addressing heat, rigidity, toolpath planning, and part geometry. Using the right strategies keeps you ahead of the solid end milling curve in machining complex aerospace parts. /episode/index/show/mtdmag/id/37440935

Ceramics optimise aerospace machining 07/17/2025

Ceramics optimise aerospace machining As nickel-based alloy parts become increasingly prevalent in the aero sector, the demand for optimised cutting tools grows. Nickel-based materials exhibit poor machinability, adhere to cutting tools, and consist of abrasive particles within the alloy. These issues result in poor productivity when using carbide tools. Henri Sevonen, Senior Industry Segment Manager – Aerospace for metal cutting specialist Sandvik Coromant, explains how new ceramic end mill technology has emerged to meet these requirements. Most aerospace parts are made from heat-resistant super alloys (HRSAs) and nickel-based alloys, which impose specific demands on engineers tasked with machining spools, turbine disks, combustion casings, and blisks. While many utilise solid-carbide end mills, these tools have limitations in performance. In the global arena, aerospace machine shops are looking for next-level technologies to deliver a step-change in productivity and/or tool life. Ceramic end mills can provide that very leap, offering up to 20-30 times more machining speed than solid-carbide tools. Such gains can be achieved because ceramic cutters retain their hardness at the high temperatures which arise when machining nickel alloys. The brazed ceramic CoroMill® 316 exchangeable-head end mill for roughing serves as a productive solution for aero engine applications involving ISO S materials. Firstly, the exchangeable head concept provides inherent process flexibility. Additionally, a six-flute version with a straight corner radius is available, delivering productive side milling, alongside a four-flute version for face milling. The ceramic substrate allows for a different cutting process in comparison with traditional solid-carbide tools. Importantly, the unique S1KU SiAlON grade is purpose-designed for the superior machining of nickel alloys, and is supported by negative geometry that provides a tough cutting edge. The latter also features a T-land for stable operations. SiAlON carries a chemical composition of aluminium oxide and silicon nitride (Al203+Si3N4), a combination that promotes high wear resistance, even at elevated temperatures. A stable set-up is recommended in all cases, and always without coolant application; machine shops should use pressurised air instead, as coolant would simply burn at the high temperatures involved. Furthermore, the use of coolant promotes thermal shocks and negatively affects tool life. Importantly, high spindle speeds of at least 13,000rpm are required. Additional recommendations include the use of down milling, as well as a programmed tool path that maintains the tool in constant contact with the material. It is clear that nickel-based alloys will play a vital role in the future of aerospace manufacturing. However, there are many challenges facing those tasked with producing aerospace engine components. It’s only through continued tooling innovations, such as ceramic end mill technology, that aerospace machine shops will be able to optimise the machining process. /episode/index/show/mtdmag/id/37440870

Complete machining alleviates the shortage of skilled labour 07/17/2025

Complete machining alleviates the shortage of skilled labour With skilled labour in short supply everywhere, it is becoming increasingly difficult to maintain or enhance productivity in metal-cutting production without complete automation. Companies will gain a competitive edge if they pay greater attention to the customer’s perspective during these ongoing labour constraints and contemplate comprehensive machining solutions. The pressure in metal-cutting production is gradually intensifying due to a decreasing number of qualified individuals in the labour market. The labour situation is likely to deteriorate as the current skilled workforce begins to retire in the next five years. Furthermore, those workers still willing to work may lack the necessary skills for many essential tasks. An effective approach for transforming shops could involve their tool partner. If tool manufacturers consider the perspectives of customers and users, they possess tools and solutions that facilitate machining operations requiring fewer staff. This is particularly relevant in machining scenarios where fully automated processes are not feasible. One forward-thinking tool manufacturer is ARNO Werkzeuge from Ostfildern near Stuttgart. The family-run company possesses a wealth of expertise derived from its proximity to customers. This is reflected in various tools that prioritise complete machining wherever possible, enabling users to rely on rapid and user-friendly tool-changing systems for both fixed headstock and Swiss-type automatic lathes. The Swabian company has recently added height-adjustable holders for back working to its product range. These holders boast several impressive features not found in conventional systems. The newly introduced height-adjustable holders for machines without a Y2 axis can be finely pre-adjusted off the machine using an adjustment device, enhancing production and machine running times whilst making the process easy to learn. The easy-to-install system comprises a basic holder, spacer plate, top holder, and coolant supply attachment. The basic holder is precision clamped and secured by a simple dovetail guide, featuring smooth surfaces to prevent chip accumulation. ARNO Werkzeuge’s new holders preserve the centre height setting when the tool holder is replaced, guaranteeing repeat accuracy and saving considerable time. Tool-changing scenarios always present challenges that can cost time and create sources of error. For trained lathe operators, these are everyday tasks. However, semi-skilled workers may lack the skills required for today’s highly developed turning processes. Tool manufacturers who consider these scenarios now will have a competitive edge. When tool changes can be entirely eliminated, tasks naturally become easier. ARNO Werkzeuge has developed fixed holders with tools for machines featuring a Y2 axis, where the adjustable axis determines the centre height. These holders are designed in collaboration with machine manufacturers to ensure optimal dimensions whilst offering high stability. The company’s patented AWL tool holder system can accommodate between two and eight tools, depending on the machine design, enabling a wide range of turning operations without human intervention. The AWL direct mount has an integrated coolant supply with two separate cooling channels supplying coolant to the cut point at high pressures of up to 150 bar. If tool changes are necessary, the AWL direct mount is supported by the AFC quick-change tooling system. Removing or fitting two-part tools requires only a few straightforward operations. Interchangeable tool holders can be fitted and removed swiftly, with only the front section needing detachment to attach the new insert. In view of the skilled labour shortage now and in the future, tool manufacturers need to rethink their approach. ARNO Werkzeuge, whose products are easy to use, adjust, change and handle, exemplifies achieving this transformation. /episode/index/show/mtdmag/id/37440845

Vertical integration powers next-day precision tooling 07/17/2025

Vertical integration powers next-day precision tooling In an industry where precision and timely delivery are paramount, Guhring UK stands out as a manufacturing powerhouse. The company’s Birmingham facility exemplifies a vertically integrated approach to cutting tool production that sets new standards for service, quality, and responsiveness in the precision cutting tool sector. “We’re very proud of the facility,” explains Chris Bush, National Sales Manager of Guhring UK. “We’ve got Guhring-made machines to make our Guhring tools – this ensures quality, consistency and complete process control.” This single-site integration encompasses the entire manufacturing ecosystem, from raw materials to finished products. This stretches from production to coatings and regrinding services. The Birmingham facility houses not only standard manufacturing operations but also specialised tool production and coating capabilities that significantly extend tool life. “We’ve got our own grinding machines. We’ve got our own coating facility,” Chris elaborates. “So once the customer has used our tools, they can come back here for regrinding. They’re ground on the same machines that they’re originally made on, coated with the same coating that they started with.” The facility’s vertical integration model provides substantial benefits to customers throughout the product lifecycle. “You get the same performance from a regrind as you do from a new tool,” Chris notes, highlighting a key differentiator in Guhring’s service proposition. When asked whether this comprehensive approach is standard in the industry, Chris is clear about their position: “We’re unique in that. The size of the factory and the fact that we have everything you need, all in one place.” Unmatched Inventory and Rapid Availability Perhaps most impressive is Guhring UK’s commitment to product availability. “We hold so much stock here, we have £5m worth of stock on the shelf,” Chris points out. “I do think it’s essential that we keep all this stock here within the UK,” Chris emphasises. “We have 45,000 standard line items, and we’ve just released a new catalogue, another big book, bringing everything together in one book. We have extensive rows of stock readily available for next-day delivery or same-day collection.” This inventory strategy is specifically designed to address the unpredictable nature of manufacturing operations. “People can’t plan for mishaps and breakages,” explains Chris. “That’s why we maintain a broad and readily available stock range. If someone needs something urgently, we can guarantee next-day delivery or even same-day collection.” This responsiveness is especially valuable in production environments where downtime incurs significant costs. By maintaining such a comprehensive local inventory, Guhring effectively serves as a strategic partner in its customers’ operational continuity. Engineering Expertise in the Field Supporting this impressive manufacturing and inventory capability is Guhring UK’s dedicated field engineering team. “Within the UK, we’ve got just under 100 people working for Guhring UK,” Chris shares. “Of those, 22 are field engineers operating across the entire UK and Ireland.” These engineers act as technical consultants, delivering expert support directly at customer sites. “This allows them to visit customers and engineering firms, where they optimise cutting data, reduce cycle times, and ensure the right tools are selected for the right applications,” Chris explains. “Ultimately, their role is to help make our customers more efficient and more profitable.” Coating Technology as Differentiator A standout aspect of Guhring’s technical capability is its in-house coating department. “It’s all about time,” Chris emphasises. “That’s why we offer 10 different coatings here, and it’s all application-specific. So, depending on the application, we’ll have the right coating that goes on the tool for that process.” These specialised coatings provide significant performance enhancements: “With the coating, we can offer four times the tool life, from a bright tool to a coated one. And it’s all under one roof.” By keeping coating operations in-house instead of outsourcing to third-party providers, Guhring ensures complete quality control throughout the manufacturing process. This integration also significantly reduces lead times, as tools do not have to leave the facility for coating. Agility in a Changing Market The manufacturing landscape continually evolves with new materials, tighter tolerances, and increasing production demands. When asked how Guhring addresses these changing market requirements, Chris points to the company’s technical foundation: “Thanks to the facility we have and the expertise within our team, we’re equipped to handle any demand that comes our way.” This confidence stems from Guhring’s comprehensive approach that Chris succinctly summarises: “From the standards to the specials to the regrinds. Any application that comes our way, we’ve got the technology to handle it.” Industry Engagement Guhring UK maintains an open-door policy for customers interested in experiencing their operations firsthand. “We have an open door policy, so any customers who want to come along and see it firsthand are more than welcome,” Chris invites. This transparency reflects the company’s confidence in its operations and its willingness to demonstrate manufacturing capabilities directly to interested parties. It also underscores Guhring’s collaborative approach to customer relationships, viewing technical partnerships as essential to mutual success. In an era where global supply chains often separate manufacturing from end-users by thousands of miles and weeks of lead time, Guhring UK’s Birmingham facility provides a compelling alternative. By combining extensive inventory, comprehensive manufacturing capabilities, specialised coating technology, and field engineering expertise in one location, the company offers a level of responsiveness and technical support that sets it apart. For manufacturing operations across the UK and Ireland, this vertically integrated approach results in reduced downtime, optimised productivity, and a tooling partner with the technical ability to meet virtually any cutting tool requirement. /episode/index/show/mtdmag/id/37440770

Hexagon advances digital manufacturing with AI-powered solutions 07/17/2025

Hexagon advances digital manufacturing with AI-powered solutions The future of manufacturing is increasingly digital, collaborative, and intelligent. This was the clear message at Hexagon’s recent ‘The Future of Shop Floor’ event, held in partnership with Mills CNC at their Technology Campus. The event demonstrated how artificial intelligence, cloud-based platforms, and data-driven insights transform traditional manufacturing operations, resulting in measurable improvements in productivity and profitability. Opening the event by introducing Nexus, the company’s cloud-based platform designed to tackle the collaboration crisis in manufacturing, Jason Walker, Hexagon’s VP of General Manufacturing, stated: “An independent Forrester report we commissioned, surveyed around 500 manufacturers from small, medium, and large-sized organisations worldwide and 97% across all those different kinds of organisations, agreed that collaboration is the key challenge that manufacturers face.” Nexus addresses this challenge through comprehensive connectivity. “Nexus is fundamentally about connectivity. It’s about joining all these different tools together within a specific function, across different functions, departments, sites, and organisations,” Walker explained. “Nexus connects to third-party tools as well, even if they are competitors of Hexagon, it builds workflows to encourage collaboration between engineers.” The platform’s design philosophy emphasises integration rather than disruption. “Nexus is designed to meet you where you are. If you’ve got a process, a tool, or a particular place where you store your data today, Nexus won’t disrupt any of that. Just join the dots to encourage and enable collaborations,” Walker emphasised. The Pro Plan Revolution Stephen Graham, Executive Vice President and General Manager for Nexus at Hexagon, revealed Pro Plan AI’s impressive performance metrics during its pilot phase. For readers unfamiliar with Hexagon’s Pro Plan AI suite, see the January 2025 issue of MTD magazine. “We’ve got ten customers engaged in a formal piloting programme at the moment, and the feedback has been stunning,” Graham announced. “Even at this early Beta Test stage, we can demonstrate something like a 70 to 75% improvement in productivity. A task that may have taken a couple of days could take just a few minutes using this powerful tool.” Pro Plan AI’s approach differs fundamentally from that of existing automation tools. “There are tools out there attempting to automate CAM programming, but they’re either trying to identify features in a CAD model using a rules-based system, or we’ve seen people trying to use generative AI,” Graham explained. “Our machine learning approach is looking through the history of programs, figuring out how you program, and replicating that based on the new geometry.” The tool’s knowledge capture capabilities will address critical workforce challenges. “Pro Plan AI captures tribal knowledge. When it’s first installed, it learns how users program CNC machines. It will program in the style of what it sees in the organisation’s history,” Graham noted. Discussing one of the early test customers, Graham adds: “This feature proved particularly valuable in a North American pilot. The company has a relatively new programmer in his early 20s who joined the company two or three months ago. Once he started working with Pro Plan AI, he suddenly contributed programmes directly to the shop floor that were on par with anything from any of the guys who have been there programming for 20 or 30 years. This not only speeds up programming times, but also demonstrates how it is closing the ‘skills gap’.” Pro Plan AI also enables new business capabilities. “You can programme a machine in a few seconds, then for a given part, you can programme every single machine on the shop floor. You can program every machine on the shop floor for every combination of tools; you can then use that to interact with your production planning systems. You can also use it to create much more accurate quotations before starting a job in the first place,” Graham explained. The improvement in quoting accuracy addresses a fundamental business challenge. “One of the big ones we heard from customers is regarding quoting. Quite a lot of guesswork goes into quoting, because nobody’s got the time to do the proper engineering work to find out how long it takes. With Pro Plan AI, even if it’s not 100% accurate, you get a pretty good idea of how long it will be on a particular machine,” Graham revealed. Transforming Quote-to-Cash Processes Hexagon recognises that efficient and accurate quoting is essential for business success—and this is one reason why ‘Paperless Parts’ has been added to the portfolio. A strategic partnership that delivers measurable business transformation for manufacturers, Jason Walker provided an extensive analysis: “Paperless Parts is Boston-based, and they are primarily in the US for now, although we are just in the process of helping them expand internationally.” The platform addresses critical inefficiencies in manufacturing’s front-end processes through comprehensive automation of the quoting workflow. The quoting challenge directly impacts manufacturers’ competitiveness. “I have asked a couple of customers exactly how long it took to get a quote out of the door before you implemented Paperless Parts. And on average, they would say about a week. So, you get an RFQ on Monday, you might only get to it by the end of the week,” Walker detailed. “The problem is that another manufacturer is getting their quote back quicker. They’re probably going to win the work, because most of the OEMs just want to fulfil their order.” Paperless Parts delivers dramatic improvements in turnaround times that directly impact business outcomes. “With Paperless Parts, most manufacturers are doing turnaround within 24, sometimes 48 hours. So that’s the difference,” Walker noted. The business impact extends far beyond speed enhancements: “One customer that is already reducing quote time from a week to 24 hours claims to be already winning 25% more work.” The platform’s functionality includes comprehensive quote management capabilities that eliminate traditional bottlenecks. “It’s an interesting space because it focuses solely on quoting, but the platform also allows for internal collaboration at a large company, which you might need when compiling a quote. You might need the engineer’s input on ‘Can we manufacture this?’ So the platform itself enables that real-time collaboration,” Walker explained. This collaborative approach ensures that technical feasibility is assessed during the quoting process rather than after the work is won. Automation features remove the burdens of manual data entry that have traditionally hindered quote generation. “It configures everything for you and automates the quoting setup process; it syncs back with your ERP system. Many customers will be using Excel spreadsheets or their ERP, but mostly the ERP’s quoting functionality is like an Excel spreadsheet. You still have to put everything in manually. So that’s where Paperless Parts is automating much of that,” Walker detailed. The integration capabilities extend throughout the manufacturing workflow. “Engineers have all that information, from the design to the integrations with our CAM software and then into Paperless Parts,” Walker explained. This smooth data flow eliminates multiple manual handoffs that traditionally delay quote generation and introduce errors. “Not only is it allowing businesses to get quotes out quicker, but it’s reducing the burden. A lot of the time, it’s the owner or the manager who’s doing the quotes, because it’s such a crucial process. You don’t want to be under-quoting. This is buying them their time back,” Walker observed. This liberation of time enables leadership to focus on strategic business development rather than administrative tasks. The European expansion is proceeding with pilot customers demonstrating similar transformative results. “We’ve been in partnership since the beginning of last year, but we focused primarily on the US last year. There will be a European launch later in the year. At the moment, we’re finding a few pilot customers,” Walker confirmed. “Early European feedback mirrors US success, it’s completely transformative to the way that they were doing things before.” Innovation and Strategic Partnership Tony Dale, CEO of Mills CNC, offered insights into the strategic partnership with Hexagon as well as the company’s forthcoming product innovations. Tony Dale says: “Our strengths are that we are an independently owned business, which makes us agile and allows us to respond to customers’ requests.” The company’s inventory management reflects its customer-focused approach. “We’ve got about 80 machines here now, but we’ve normally got around 200 machines in stock. So, the availability of machines is key for customers these days; nobody wants to wait. So that agility and stock holding enables us to support customers when they need that technology for that new contract,” Dale explained. “The relationship with Hexagon is effective. It enables us to provide a solution to the end user, not only supplying the machine tool but also programming it, reverse engineering it, and inspecting components, all of which contribute to our automation for end-to-end production,” Dale explained. Looking ahead, Mills has significant product launches planned. “Key focuses for us this year are launching two brand new models. We’ll be holding an event later in October. We’ve got the DNX 2100 entry-level multi-tasking machine, and it’s quite a big launch for us because we’re seeing how customers want to leave tools set up on the machines to reduce setup and changeover times,” Dale announced. The DNX 2100 addresses specific market evolution. “If you can quickly change your jaws and programme, with your tools already set up in that carousel, this is faster than traditional block tools on a turret. We already do 5-axis mill/turn machines, but this is more entry level for customers upgrading from a traditional turret lathe to get into the realms of multitasking,” Dale explained. Dale linked the new machine to broader industry trends that Hexagon is also tackling: “With the skill shortages of engineers these days, we’re finding that this is a growing part of our business offering.” The second major launch involves an evolution of existing technology. “We also have the second generation of the DVF 5000, which will launch simultaneously. It is a high-speed, high-accuracy 5-axis machine,” Dale noted. We will publish the second instalment of this event in the September issue of MTD Magazine. It will highlight the new Datanomics production monitoring suite and provide an update on the success of Hexagon’s Benchmarking tool, a year after we first discussed the tool at MACH 2024. /episode/index/show/mtdmag/id/37440755

Measurement cycles carved in stone with precision 07/17/2025

Measurement cycles carved in stone with precision Reitz Natursteintechnik KG plans, designs and manufactures highly precise machine components from granite. To ensure efficient processing, Vericut is employed, offering the advantages of reliable production and a reduced workload. The origins of Reitz date back to 1946, when Herrmann Reitz began extracting raw stone from his own quarry in Asslar. With the arrival of his son Friedel, gravestones were produced from 1958 until the introduction of the first granite surface plates that changed the business model, leading to the establishment of E. Reitz Natursteintechnik e.K. in 1986. Today, Christopher Reitz, the fourth generation and current Managing Director says: “Today’s machine components combine the million-year-old material stone with cutting-edge technology. For 35 years, we’ve been manufacturing components from granite and offering system assembly and custom solutions and complete systems.” The company currently employs approximately 140 people with clients in the semiconductor, optics, general mechanical engineering, metrology, printing, and medical sectors. Competitive Edge with Granite “We’ve been experts in processing natural hard stone for over 60 years—a tradition we’re proud of,” says Reitz. In mechanical engineering, particularly in machine tool construction, achieving optimum precision and performance is crucial. The machine bed is pivotal. “Due to its properties, granite offers clear advantages that neither steel nor mineral casting can match: stability, temperature resistance, vibration damping, and accuracy make granite the ideal material for machines,” explains Reitz. It’s no surprise, therefore, that granite is commonly utilised in measuring and test stands, as well as coordinate measuring machines, for components such as surface plates, tables, and machine frames. In-House Built Gantry Milling Machines “Our granite comes mostly from South Africa, Spain, France, and Austria. It’s either delivered in pre-cut slabs or as raw blocks we cut in-house. The workpieces vary in size, from 250 by 250mm up to 13m. The largest we ever made was 13 by 1.5 by 1m and weighed about 65 tons,” adds Reitz. To accurately process such blocks, Reitz relies predominantly on machines developed and constructed in-house: four gantry-type milling machines and two 5-axis gantry machines, all controlled by Siemens 840D. To ensure safe, fast, and precise granite machining, the company uses Vericut simulation software. “Granite is a natural product, so the surface is never flat. To prevent tool collisions during processing, we developed a process with Vericut that virtually eliminates this risk,” explains Reitz. Stephan Meurisse, Marketing Manager at Vericut, Deutschland, adds: “Downtime, damaged tools, costly collisions, unusable parts, long setup times, wasted materials—all of that costs time and money. Vericut helps our customers avoid these time and cost traps.” “Vericut eliminates the need for manual setup, saves valuable operator time, and protects our machines,” says René Maschlanka, responsible for sales and project management at Reitz. Intelligent Process Flow Granite blocks up to 13m long are typically delivered with +3 to 5mm oversize. They are then machined to a flatness of 20 to 5µm. Since granite is very hard (Mohs hardness 6–8), only 0.1mm of material can be removed per cut. After a visual inspection, the operator selects a measurement point pattern, generating two automatic measurement programmes in the CAM system. The first determines the block’s position, and the second maps its surface—both via probing cycles,” says Maschlanka. Each probing cycle uses valuable machine time, so it is performed as infrequently as possible, yet as frequently as necessary. The resulting programs are converted into NC code and simulated in Vericut. Once verified, the programs are run on the machine. “The returned measurement points describe the actual surface condition, and from that data, a machining programme for a precise cuboid is automatically derived, then simulated in Vericut before execution,” explains Meurisse. The completed cuboid is then drilled for guide rails, drives, spindles, sensors, and attachments. Once the stainless steel thread inserts are glued in, the component is sent to the climate-controlled precision lab for final machining. “Naturally, these final programs are also validated with Vericut,” Maschlanka emphasises. “We use a special CAM system for granite processing. We built the interface to Vericut ourselves. It lets us precisely capture the position and shape of the workpiece and simulate automated steps without manual setup,” says Maschlanka. The simulation assists in detecting unnecessary movements, clamping errors, and incorrect tool usage before they occur. Some machining processes at Reitz can take over 40 hours. Previously, the operator had to stand by the entire time. Now, they simulate on a PC, press start, and only check in occasionally. “Now our programmers and operators are far more relaxed—they know their programs will run safely, with no crashes. The integrated Vericut Reviewer shows us when that approach makes sense,” says Reitz. Vericut Reviewer allows users to interact with the simulation file on any Windows PC or tablet. It helps build trust in new processes. “Operators, shop floor staff, or engineers can review simulations and confirm the project is correct before running it on the machine. Our staff love the Reviewer. It shows the full machining sequence, highlights critical steps, and helps with prep, like planning supports, tools, and clamping,” says Meurisse. Thanks to Vericut, tool breakage and collisions due to programming errors are a thing of the past at Reitz Natursteintechnik KG. “Vericut is a huge help and a great tool. It’s easy to use, gives programmers confidence, avoids costly collisions, and keeps our operators at ease,” summarises Christopher Reitz. /episode/index/show/mtdmag/id/37440725

More than just machines 07/17/2025

More than just machines Starrag provides a full range of manufacturing solutions, utilising its own in-house components as well as specialised tools. The high-quality Starrag machines developed and manufactured in Rorschacherberg, Switzerland, are impressive. However, the machines represent just one facet of a diverse portfolio that encompasses technology, software, clamping concepts, and carbide tools, which are also manufactured in-house and are often vital to success. Starrag’s headquarters in Rorschacherberg specialises in creating high-performance machining centres for aircraft and turbine manufacturing. Nonetheless, the company offers a broader range of solutions. Years of accumulated expertise from various projects is evident in the numerous components developed internally: from carbide tools and RCS CAM software for blades to clamping technology, fixture construction, automation solutions, and host computer technologies. “This ‘full package’ sets us apart from other suppliers,” says Sofian Regaz, Starrag Sales Manager for Aerospace & Turbine Technology. “We don’t see ourselves purely as a machine manufacturer, but as a solution provider for production processes in the aerospace and turbine sector. This ranges from standalone machines to flexible manufacturing systems, which customers can obtain from us as a one-stop shop.” Gaining a competitive edge from tools tailored to the process Sofian Regaz is primarily responsible for product management and sales of Starrag tools. “Here in Rorschacherberg, we have spent many years developing and grinding carbide milling cutters for aircraft and turbine components made from difficult-to-machine materials such as titanium, Inconel or high-alloy steels.” Though Starrag offers a small range of standard tools, over 90% of the company’s tools are custom-made products. These tools are tailored to specific machining processes that fully embrace the component, the machine, the material, and other considerations. “It makes a huge difference whether I adapt my NC program to a catalogue milling cutter or design the tool in terms of the cutting edge length, corner radius, flank angle and coating. This enables us to deliver the optimum machining process. Our customers enjoy great success with this,” says Sofian Regaz. Always available to serve customer needs Starrag sells most of its machines as part of a manufacturing solution for a specific component or component family, so the corresponding specialist tools are usually supplied with them. This incorporates an explanation of why the tools are designed in a particular way and the expertise on which they are based. The Product Manager adds: “The customer needs to know how their tools differ from catalogue tools and the impact these differences have. They also need to understand that the advantages of our tools cannot be found with other suppliers.” This expertise is no coincidence. Starrag maintains a very close, partnership-based relationship with its customers and supports them throughout the production process and beyond the warranty period. “This means that if, for example, a component is due to be changed and the machine needs to be set up for a new process, we are still by our customer’s side to offer new customised tools as necessary,” assures Regaz. Starrag has a distinct advantage over traditional tool manufacturers. Tools are both developed and ground at the Rorschacherberg plant, which also houses the Aerospace and Turbine Competence Centre (ATCC). The 2,000m2 centre is equipped with all the latest 5-axis machining centres from the Starrag NB, LX, and STC series. Sofian Regaz explains: “We use these machines for a wide range of our own trials and trials for our customers, as well as for developing and optimising processes and, of course, for our analyses and tool tests. We even take on small series production on behalf of customers.” For the tool team, this means they can reproduce the customer’s processes 1:1 on original machines and optimise the tools before delivery. Time and again, customers confirm that this saves numerous transport routes and, in turn, a significant amount of time and money. “If corrections to the tool are still necessary, we can react and adopt changes very quickly because we have our own grinding shop,” says Sofian Regaz. “We achieve incredibly quick response times, sometimes just in half a day.” Tool expertise for better machining results The ATCC is an important meeting place where Starrag technologists, machine operators, automation specialists, tool specialists, and customers come together. Starrag offers comprehensive support in programming the machines, managing processes, and optimising subsequent processes. For the tool team, this is a valuable source of expertise. “This is where we find out how the market is evolving, how materials are changing, what the blanks of the future will look like and what requirements components will have to meet. This allows us to get ahead of the game with our tool developments and offer our customers solutions early on.” Starrag is also well-positioned worldwide in tool servicing. Starrag has partnered with Oerlikon Balzers to save customers time and money by providing on-site regrinding and recoating services for Starrag in America and Asia. This is an important factor for Sofian Regaz: “We offer a similar service in-house as well, but customers can save themselves the long journeys from overseas by using our partner offer.” “Customer feedback on our tools is consistently positive,” mentions Sofian Regaz. He received a special confirmation of success from Honeywell Aerospace Ireland, where Starrag had the chance to work as a tool problem solver. The starting basis was that tool wear was very high when machining a titanium turbine blade. No more than ten components could be machined with the existing milling cutter. That’s when the engine manufacturer invited important tool manufacturers to get a handle on the problem. The best supplier managed to increase the service life to 20 components. And Starrag? “Our special tools produce 40 components,” reports Sofian Regaz. “Honeywell considered this worthy of not only a contract, but also an award. In June 2024, we were awarded the ‘Kaizen of the Month’ prize.” Success leads to growth The tool business has experienced tremendous growth in recent years. This success is not solely due to stories like the Honeywell contract. The expanded product range has also played a significant role in this. While Starrag used to produce only end mills, torus mills, and conical ball nose mills, today the company also grinds cylindrical and barrel ball nose mills, lollipop mills, barrel cutters, and chamfer milling cutters. Additionally, there is a range of high-feed, plunge, and various form milling cutters that can be applied to turbine blade roots. To generate further growth, Starrag will offer special tools for machining aluminium alongside tools for more challenging materials. Sofian Regaz’s team is also strengthening its business development: “Our process expertise in aircraft and turbine construction is so extensive that we can also enjoy great success with our tools on third-party machines. And we are already in talks with other Starrag sites. In the future, we want to utilise their machining centres and their expertise to produce special tools for other industries.” /episode/index/show/mtdmag/id/37439695

The right tool for the job 07/17/2025

The right tool for the job The grinding specialist Kellenberger, part of the Hardinge Group, has developed a groundbreaking innovation to simplify the automation of grinding workpieces of varying lengths for a tool manufacturer. For a considerable time, users have been interested not only in machines but also in machining solutions. Regarding these solutions, the machine manufacturer is responsible for the entire process, covering all upstream and downstream operations. The continual advancement of automation in production processes also presents challenges to the flexibility of machine tools. This innovation can be explored through UK specialists DF Precision Machinery. At the Kellenberger base in Goldach, Switzerland, the emphasis is on customer-specific system solutions. There, highly integrated cylindrical grinding systems for large-scale production are fitted with automatic loading, measuring devices, and other supplementary operations as required. Each year, a diverse range of turnkey solutions are delivered to customers, including automotive manufacturers and various suppliers. At the Kellenberger production site in Goldach, the ‘Customer-Specific Special Construction’ department develops solutions that are especially challenging and not yet available on the market. A well-known tool manufacturer was seeking a solution for the automated grinding of workpieces such as drills and tool holders. The challenge in machining lies in the fact that the parts have varying lengths. This necessitates that the clamping force be adjusted manually for the required length compensation during grinding. Automated machining is therefore not feasible in this context. The designers in Goldach met the challenge and rose above the competition. They developed a positioning axis (Z2 axis) that ensures automatic length compensation by a robot or gantry loader during the fully automatic loading. The Z2-axis is mounted on the Z-axis and moves accordingly. The automatic zero-point shift is implemented using a longitudinal pushbutton (KEL-Pos). Dressing is not permitted on the Z2-axis. The grinding dressers are mounted on the Z-axis. Workpieces with up to 250mm diameters and length compensation ranging from 50 to 300mm can be machined. Non-circular parts can also be ground and can be centred fully automatically. In summary, the machine features a 250mm hub with a minimum centre height of 250mm and an axial force ranging from 50 to 1200n. The load capacity for live spindle grinding is 200Nm for a maximum load of up to 150kg. When using a synchronous tailstock (available as an optional feature), no chuck is needed due to the friction drive. An in-process measuring control covers a diameter range of 25mm. Manual retooling is no longer required. The Z2 axis was developed for the universal internal and external cylindrical grinding machines of the K100 and K1000 series with Fanuc control. The obvious question is: can the Z2 axis be retrofitted onto such machines? Patrick Gähler, Design Engineer at Kellenberger, answered: “Retrofitting is impossible because the function of the Z2 axis must be incorporated in the design of the machine beforehand.” In the showroom at Kellenberger in St. Gallen, interested customers will have the opportunity to see a KELLENBERGER K100 with Z2 axis, on which tests can also be carried out. /episode/index/show/mtdmag/id/37439670

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