ELE Advanced Technologies, which specialises in applying non-conventional machining techniques to the production of industrial gas turbine components used in aircraft and power generation, has invested £2 million in an automated VIPER grinding cell at its Colne factory.

The equipment is devoted to high efficiency machining of complex fir-tree root forms and shroud end features on nickel alloy turbine blades, compressor blades and guide vanes. Leading names in aerospace and land-based turbine manufacture are customers, including Rolls-Royce, Avio, Pratt & Whitney, Siemens and Alstom.

Peter Calderbank, Operations Director at ELE, commented, "We have traditionally used conventional creep feed grinders to manufacture industrial gas turbine components.

"Whilst this method is efficient for large volume production, the market is increasingly demanding smaller batches, delivered just-in-time.

"Set-ups are quicker and completed off-line, lead times are shorter, the amount of work-in-progress is less and tooling costs are lower, leading to much more economical machining of high accuracy features in exotic alloys."

The automated process at ELE is based on a Makino 5-axis A99e machining centre configured for creep-feed grinding using small, profiled wheels exchanged from the tool magazine. The turnkey cell includes equipment for continuously dressing the grinding wheels, an Erowa palletised workholding system and a Fanuc 6-axis robot for exchanging fixtured components automatically.

More features can be ground in a single set-up on a VIPER machine than on a conventional creep feed grinder, saving refixturing time and promoting higher accuracy and repeatability.

Typically, conventional grinding of root and shroud features on a nickel alloy casting requires four separate operations on CNC grinders, plus there is a significant amount of handling time. The same component can be completed on the Makino A99 in two operations and speed of manufacture is increased further by the higher metal removal rate.

Another useful benefit of VIPER grinding on a machining centre is that other tools can be brought into use from the same magazine that houses the grinding wheels. So, for example, if additional metalcutting operations such as milling and drilling are required, these may be completed in the same cycle without manual intervention.

VIPER grinding has been very successful at ELE. Several new contracts to be machined on the Makino A99 have been secured, on the basis of reduced tooling costs and very short lead times.

The ISO 9001-2000 accredited company is one of only a very few manufacturers worldwide offering capillary, laser and EDM drilling as well as shaped tube electrolytic machining alongside conventional machining such as high-speed CNC milling and turning. ELE also have a factory in Slovakia producing complex turbocharger components and other components in small volumes for the automotive industry.

Global Heat Transfer <http://www.globalheattransfer.co.uk/> , the thermal fluid specialist, has created five vacancies at its Cold Meece Estate headquarters in Stone. The increased demand for personnel follows a prosperous period of growth and the company plans to double in size over the next 12 months.

The thermal fluid specialist, a division of Global Group <http://www.globalgroup.org/> , is looking to recruit candidates from a range of professional backgrounds with various levels of experience. A proven sales executive is needed as is a telesales executive with experience of working in customer relationship management. A new business manager with a proven background in engineering and/or technical sales and a marketing executive is needed to implement marketing campaigns. Finally, an experienced engineer with a background in similar industries is needed to complement the team.

Global Heat Transfer provides a comprehensive range of services for the thermal fluid industry including sampling, analysis and fluid delivery as well as system drain down, cleaning and waste management. It also specialises in on-site maintenance, system design and installation. The company works with a growing client base <http://www.globalheattransfer.co.uk/who-we-work-with>  from industries as diverse as marine, petrochemicals and pharmaceuticals. It also works in the solar, manufacturing, print and food processing sectors.

“Although the work that we do here is niche, it is of huge relevance to the process industries in which we work,” explained Clive Jones (40), managing director at Global Heat Transfer. “Process engineers don’t realise that the services we supply are crucial in helping our customers meet health and safety regulations and operate lawfully. Our understanding of thermal oil management systems enables us to simplify complex issues and deliver the most beneficial solutions to our customers.” 

“Staffordshire and the Midlands overall are particularly strong markets for us due to the number of food processing and manufacturing industries in the area,” continued Jones.  “Without this market we would not be experiencing our unprecedented growth. So we see it is important to feedback this value into the community,” Jones concluded. 

If you’re interested in these any of these vacancies, e-mail your CV to Clive Jones at cjones@globalheattransfer.co.uk or visit the Global Heat Transfer’s website www.globalheattransfer.co.uk 

Delcam will demonstrate its new Vortex strategy for high-speed area clearance on booth E-3222 at the IMTS exhibition to be held in Chicago from 10th to 15th September.  Vortex will be the major enhancement for the 2013 release of Delcam’s PowerMILL CAM system for high-speed and five-axis machining that will be launched at the show.  The new strategy will also be added to the FeatureCAM software for feature-based programming and the PartMaker system for programming Swiss-type lathes and turn-mill equipment later in the year.

Vortex, for which Delcam has a patent pending, has been developed by the company specifically to gain the maximum benefit from solid carbide tooling, in particular those designs that can give deeper cuts by using the full flute length as the cutting surface.  It can be used for two- and three-axis roughing, three-plus-two-axis area clearance and for rest machining based on stock models or reference toolpaths.

Like other Delcam roughing strategies, Vortex toolpaths are calculated to give more efficient machining by following the shape of the part and by keeping air moves to a minimum.  This is particularly important for rest machining operations.

One fundamental problem with conventional area-clearance strategies is that the optimum cutting conditions only occur during a straight-line cut.  Any internal corners within the model significantly increase the engagement angle of the cutter.   To protect the cutter, this increase needs to be balanced by setting a lower feed rate.  The user then has the choice of using this lower rate over the whole toolpath, which increases the machining time, or varying the feeds and speeds as the cutter moves around the model and so increasing wear on the cutter.

Unlike other high-speed roughing techniques that aim to maintain a constant theoretical metal-removal rate, the Vortex strategy produces toolpaths with a controlled engagement angle for the complete operation.  This maintains the optimum cutting conditions for the entire toolpath that would normally be possible only for the straight-line moves.  As a result, the cutting time will be shorter, while cutting will be undertaken at a more consistent volume-removal rate and feed rate, so protecting the machine.

Because Vortex toolpaths have a controlled engagement angle, tools will never be overloaded and so will achieve the maximum tool life.  Shock loading caused by changes in the contact angle is minimised, preventing chipping of the flutes.  In addition, the stability of the cutting conditions gives more consistent edge temperatures, so prolonging the life of the tool coating and removing heat damage to the surface of the part.  Finally, the ability to use stepdowns of up to two, or even three times, the tool diameter spreads the tool wear evenly over the cutting surface of the tool, again contributing to longer tool life.

“Anyone using the Vortex strategy will be able to hear the difference immediately,” claimed Mark Forth, Product Manager for Delcam’s Advanced Manufacturing Solutions.  “Conventional roughing produces a sound of varying pitch, which indicates tool overload and chatter, while Vortex roughing gives a constant pitch, showing that the tool is operating under consistent conditions.  Users will also be able to see the difference in the regular size and thickness of the chips produced, providing further evidence of the consistency of the cut.”

The new Vortex toolpaths benefit from the general advantages of PowerMILL, including support for 64-bit computing and multi-processor operation to minimise calculation times, plus the comprehensive options for leads and links.  Furthermore, they can be used in association with the step-cutting strategy introduced in PowerMILL 2012 R2.  This approach minimises the terracing that can result from using a large stepdown by moving back up the part and automatically generating extra toolpaths to remove additional material at intermediate slices.  It optimises the amount of material that can be removed with a single tool as well as helping to maintain a more consistent removal rate by increasing the feed rate for the intermediate slices.

Trac Measurement Systems has added Delcam’s PowerINSPECT inspection software to the range of metrology programs it offers.  Customers will be able to specify the Delcam software on equipment from Trac and on devices that are being upgraded and calibrated by the company.

Trac Measurement Systems, which is part of the Trac Group, recently invested over £1 million on a new site based at the Telford Science and Technology Park.  As well as providing state-of-the-art facilities for its existing employees and customers, the move will be a key element in the expansion of the company’s measurement services. 

“The addition of PowerINSPECT to the range of software that we can offer to our customers will further help our position as a leading supplier of measurement systems, services and technical support,” said Michael Parry from Trac.  “We anticipate that the most interest will come from companies using articulated measuring arms, as PowerINSPECT works particularly well with those devices.”

“We are pleased that Trac has become the latest metrology company to offer PowerINSPECT to its customers and expect significant sales as a result of our relationship,” added Delcam UK General Manager, Steve Creron.  “The staff at Trac have an excellent reputation for their expertise and the service they offer, while the recent investment in the Telford site shows how ambitious the company is.”

FROM CHILD’S PLAY

A study of how infants acquire language skills has informed development of technologies used in critical computing systems for the automotive, maritime and space industries.

In his free inaugural lecture on Tuesday, 17 May, Professor Michael Pont from the University of Leicester’s Department of Engineering will describe how his theoretical University work has resulted in practical ‘real-world’ applications.

Head of the Embedded Systems Research Group, Professor Pont will provide an overview of a 25-year research programme which began by exploring some of the neural mechanisms involved in the early stages of human language acquisition and which now involves the development of ‘embedded’ computing systems, which are used to control safety-critical applications, such as passenger aircraft.

During the talk, he will explore some of the common threads which link these apparently disparate research areas.
Professor Pont explained:

“I’ve been involved in a very wide range of research projects over the course of the last 25 years.  What I hope to do in this talk is to give people a flavour of some of the pleasures and challenges of such projects. 

“I also hope to be able to make it clear that university projects which may – initially – appear to be very abstract or theoretical can sometimes lead to very real practical benefits.

“For example, my own work began by trying to understand how human infants acquire language abilities and has resulted in the development of an ultra-reliable computing platform which is now being used to improve the safety of automotive, maritime, aircraft and space systems.”

The lecture, which is free and open to the public, will be held at 5.30pm in Lecture Theatre 1 in the Ken Edwards Building, University of Leicester

Established in 1962, Wavin Limited is the UK’s leading supplier of water management, plumbing, heating and drainage systems for the Building, Construction and Utilities markets. Highly respected within the Construction Industry, Wavin has earned a reputation for innovation and has an extensive product portfolio under the OSMA, Hepworth, Thermoboard, Intesio, Certus and Hep2O brands.

As the company who invented the first push-fit plumbing system, through its famous Hep2O brand, Wavin remains the leader in the field. Hep2O is an innovative push-fit polybutylene system for domestic hot and cold water supply. Hep2O is designed to enable professional plumbers to achieve faster, safer and more cost effective installations, while ensuring reliability through long service life. So confident is the company in the quality and technical ability of its Hep2O components, they are covered by an industry leading 50 year guarantee. 

Hep2O products are precision-manufactured in Wavin’s high-tech Doncaster plant using the most advanced injection moulding and extrusion machines. To ensure the absolute quality of the range’s components a strict quality control system is adhered to. To help guarantee the reliable sealing characteristics of all Hep2O fittings, the range’s components have extremely demanding dimensional tolerances. When the need arose for a reliable way of precisely measuring the critical internal diameters of Hep2O fittings, John Templeman, Quality Supervisor of Wavin, Doncaster, contacted Bowers Metrology UK.

John explained “The British Standards Institution has issued certificates registering Wavin as a firm of assessed capability, with a quality management system which meets the requirements of BS EN ISO 9001. In addition, all of our products comply with or exceed relevant British and European standards to ensure reliability and long-lasting service. Our policy of continuous improvement means that we are constantly investigating ways to improve our processes. Typical of our unremitting quest for progress is our recent purchase of an advanced Bowers Bore Gauging system.

“Although previous traditional methods, such as the use of plug-gauges gave us a good indication of size and fit, we were looking for an advanced internal measuring system that would increase our gauging capability and allow us to further control our process.

“The pressure exerted by many of the available measuring systems precluded their use on our products, as they are liable to deform some of our thinner walled plastic components. To help overcome this problem, Bowers was able to reduce the spring pressure of its Digital Pistol Grip XT Bore Gauges and to retrofit a depth stop to speed-up operation. 

“As we need to keep detailed records of our measuring routines and perform SPC, the digital nature of Bowers XT Bore Gauges enables the rapid downloading of all measuring results to our software. In-fact, Bowers’ understanding of our requirements and willingness to adapt its standard products to our needs, lead Bowers to suggest the fitting of ‘wireless’ modules to our new gauges, enabling the sending of measured data without the need for a physical link.

“Now in constant use, Bowers’ adapted Bore Gauges have proved a great success and are making an excellent contribution to guaranteeing the continuing quality of our output.”

Bowers Metrology’s state-of-the-art XT Xtreme Bore Gauging range boasts advanced electronics that have an impressive IP65 rating. This renders them resistant to coolant, water and airborne particles and makes them ideal for use within hostile measuring environments, such as close proximity to Machine Tools. 

Amongst a long list of useful features incorporated into these, radical tough instruments are a clear digital display, ergonomic pistol grip handle, metric/inch conversion, an RS 232 output and hardwearing extended travel carbide measuring anvils. Available to measure sizes from 2mm – 500mm, Bowers are also able to manufacture inexpensive ‘one-off’ XT instruments to cater for many other internal measuring applications, such as threads, grooves, and splines.    

Their ‘Nemesis’ at MACH 2012

The Bowers Metrology UK staff were kept busy demonstrating the recently launched Nemesis 9000 Hardness Tester Range, throughout the recent MACH 2012 Exhibition.   

Making a UK exhibition debut, the Nemesis 9000 Series of multi-purpose hardness testing instruments is based on the most up to date hardness testing technology. Featuring a modern design with excellent access for large components, Bowers’ advanced new product delivers high-precision combined with high-definition imaging, creating an almost unlimited field of application.

Using a load-cell, closed-loop, force feedback system, Bowers’ new hardness tester range is capable of manual or full scale automated operation. The flexible testers are suitable for a wide range of applications including Vickers (HV), Knoop (HK), Brinell (HB), Rockwell (HR), Vickers depth measurement, Brinell depth measurement and Ball indentation hardness.

The Nemesis 9000 Series boasts a wide range of test-load/force applications, ranging from 500gf to 3000kgf and feature descending test heads with automatic workpiece detection and free definable, manual or motorised 6 position turrets, for objectives and indentor choice.  

For ease of viewing and control, a large adjustable 15’’ industrial touch screen, or 22’’ LCD screen with mouse is provided. A high-definition Innovazoom optical system, providing images of 0.7x to 1000x magnification, is also supplied as standard.

User friendly, PC based Innovatest Impressions, hardness testing firmware and a database file system allows for class-leading ease of operation, whilst a built-in hard disk offers an almost endless file storing capacity.

Bowers claims that the universal nature of its new Nemesis 9000 series hardness testers mean that they are applicable to a wide range of industrial and commercial sectors including aerospace, automotive, production lines, general quality assurance and laboratory use. 

Tried and tested designs and components used by leading global machine tool manufacturers have been selected by Averex Automation, Taichung (www.averexcnc.com), to produce the Akari HS-450i horizontal-spindle machining centre (HMC). By choosing only the best constituents and coupling them with a lower cost manufacturing base in Taiwan, the company is able to build a very high precision machine at a competitive price.

The twin-pallet, 4-axis HMC was originally aimed specifically to fulfil a requirement in the American market. Over 100 have been sold in the US as well as in European countries including France, Italy and Germany, but none yet in the UK. To address this, Whitehouse Machine Tools has been appointed sole UK sales and service agent under an agreement signed shortly before MACH 2012.

A novel design feature is the machine's ability to be expanded retrospectively in the field, easily and affordably, from two to six pallets and from 80 through 120 to 220 tools in about one day.

The result is a highly flexible manufacturing centre that can grow with a user's business to allow extended periods of high-efficiency, unmanned machining. Large batches, small-lot multiple-part runs, and even ones and twos may all be produced cost effectively. Unusually, both 400 and 500 mm pallets can be used at the same time, offering additional flexibility for oversized parts and fixtures.

Of extremely high quality and precision, the 12-tonne HMC is built to exacting standards and includes thermal control of ballscrew nuts, thrust bearings, Y-axis servo mounting and spindle cartridge by means of recirculating, chilled oil. The machine also boasts hand scraped surfaces for mounting the ballscrew bearing blocks and roller bearing slideways, plus a host of other top end features.

An air/oil mist system delivers precise, pressurised lubrication to the ballscrews, roller guideways and spindle bearings, reducing thermal growth and allowing cutting accuracies of 2.5 microns and repeatability of 2 microns to be maintained. Circularity and roundness are quoted as 3.6 and 2.1 microns respectively if the machine is installed in a temperature controlled environment.

Only top quality components are used, such as the single-piece FCD600 castings for the spindle and pallets, Tsubaki ballscrews, THK heavy duty roller guideways, Tsudakoma rotary table which provides a full fourth axis, BIG Plus 40-taper spindle with face-and-taper contact coupling, Kosmek tapered cones on the automatic pallet changer which also has high pressure air clean, and Fanuc 31i NANO control.

The machine is also fast. It has a 15,000rpm / 22 kW direct drive spindle and one-second servo-driven tool change, extending to three seconds when probes, special boring bars or heavy tools are being exchanged. 1g linear acceleration to 60 m/min cutting feed rate around the 640 x 610 x 680 mm working volume ensure minimal idle times. Maximum workpiece size is 750 mm diameter by one metre high.

Despite the continuing effects of the economic downturn on business, the UK Asbestos Training Association Ltd (UKATA) reports a surge in new Memberships, prompting a reorganisation of the Associations management structure in order to respond to the demands and offering hope of a brighter outlook for the industry.

UKATA is a leading authority in asbestos training in the UK and has gone from zero Members just a few years ago, to now having over 130 fee paying Members with many more Membership applications pending.

This situation has led to the recent appointment of Terry Barker as the new Technical and Operations Manager to help oversee and support this influx of new members and help create a platform for further strategic growth and development at UKATA.

Forthcoming new legislation is likely to mean the demand for Training and Consultancy services offered by Members will only increase further, which is another force driving new Membership applications.”

UKATA continues to welcome applications from new members who meet the Association’s strict membership criteria; which are essential for those who work in such a key area of the Health and Safety industry.

“UKATA has established its current high reputation and position in the market by upholding the highest possible standards of corporate governance and compliance within the organisation,” added Terry. “This is evidenced by UKATA’s continued success in attracting a healthy flow of new Members, despite the recession.”

UKATA is moving into a new phase of development and will shortly announce the application criteria for the appointment of its first ever permanent CEO. UKATA is always keen to talk to prospective Members who are 100% committed to the highest professional standards. For further information on UKATA, visit www.ukata.org.uk

Lead generation was up on the new-look Roemheld stand at MACH 2012.  The company’s new, larger stand, in a new location in Hall 5, prompted a great deal of interest from visitors to the show.

Bill Neal, Managing Director of Roemheld (UK) Limited, said:  “We received a large number of enquiries at the show and over 35% of these leads were new companies to us.  A number of orders for vices were actually placed during the exhibition, which was an excellent result.  In fact, the company has been doing so well over the past year or so, we are looking to recruit someone new to expand our sales team.” 

As well as exhibiting new launches within its core workholding product ranges, Roemheld’s stand also showcased its new range of E-Tec products alongside its flexible fixturing system (Pogo stick), Jergens vice systems and Modulog assembly and mounting products.

To find out more about Roemheld’s range of workholding solutions, go to www.roemheld.co.uk or telephone 0121 453 1414