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years of manufac-turing
technology in-Sales Of� ce: 01322 221144Joe Opitz, Sales Director: 07967 [email protected]
Paula Martin, Sales Manager: 07967 [email protected]
Editorial Of� ce: 01322 221144Andrew Allcock, Editor: 07917 [email protected]
Publisher Jon Benson: 07545 [email protected]
MA Business LtdHawley Mill, Hawley RoadDartford, Kent, DA2 7TJ01322 221144
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THE INDUSTRY’S NO. 1 PRODUCTION EQUIPMENT JOURNAL APRIL 2017 ISSUE 1
ReTEC2017
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UK INITIATIVE EXPLOITS MAGNESIUM’S FLIGHT CLEARANCE
Bosch Rexroth puts on a show in Manchester
Industry 4.0 demonstrator
Bystronic’s rules for better bending
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I N S I D E T O O L I N G & W O R K H O L D I N G S U P P L E M E N T
UK INITIATIVE EXPLOITS MAGNESIUM’S FLIGHT CLEARANCE
ALUMINIUMALTERNATIVE
Fast manufacturingMcLaren-Honda takes 3D printing for a spin
Hardware+softwareSandvik Coromant’s modern combination
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Introduction
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Industrial strategyMeeting draws
varied input
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Mitsui Seiki (2D CNC, 0844 871 8584) has produced the � rst commercial unit of a machine tool that uses a novel, high power electro-
erosion process to rough-cut aerospace alloys such as titanium in a fraction of the time taken by traditional metalcutting techniques.
For example, a titanium alloy cutting operation that normally takes 45 minutes can be � nished in three with the new technology, according to an article published during March 2016 on GE’s public relations news
website, GE Reports (http://www.gereports.com).At a 2D CNC Open House event in November last
year, Tom Dolan, vice president of GE’s machine tool partner in the project, Mitsui Seiki (USA), pointed out that aero-engine bladed disk, or blisk, manufacturing is a particularly exciting application of the technology. He said: “Estimates of the machining hours that are required to produce all of the blisks needed to support [Boeing and Airbus single-aisle] aircraft programmes alone … are in the millions. If one can take a major portion of that away by reducing the roughing cycle time, it’s a huge cost saving.”
Blue Arc could similarly open up the possibilities to affordably manufacture new classes of aerofoils that offer performance advantages but that previously have been too slow or expensive to mechanically machine.
The process is carried out in air with an electrode held in the machine tool spindle; the working end is doused by through-spindle coolant that functions as an electrolytic � uid. Operations such as slotting, pocketing, drilling and facing are performed. Although metal surrounding the cut part may be structurally changed
(burned) by the process, that so-called heat-affected zone would be removed during subsequent traditional semi-� nishing and � nishing metalcutting cycles, without having to re� xture the part. The cutting process imparts less stress on blisk-type components than traditional tools, says the GE Reports article.
Another element of cost saving is in tooling costs, as processing hard-to-machine materials tends to consume large quantities of relatively expensive cutting tools. In contrast, the required electrode, which is consumed during the process, costs much less than do milling tools, says Dolan, but still offers a working life greater than a factory shift, according to the GE Reports article. It goes on to claim that Blue Arc would cut machine tool capital costs by 30%, and the cost of cutters by 70%.
Removing quantities of alloy material at speed requires a great deal of electricity, much more than would be required by mechanical roughing cycles. Given Blue Arc’s speed advantage, though, its total energy consumption on a part-for-part basis would still be signi� cantly less than a standard traditional milling process, Dolan says.
First introduced in 2011, the Blue Arc technology has since been tried out by GE businesses and customers to make Inconel and titanium parts, says GE Reports. Certainly the current machine design has moved on from an earlier 2011 iteration of the same name that was more similar to EDM and employed the process vertically, submerged in an electrolyte bath (https://is.gd/apizow). GE originally invented and re� ned the technology, thanks to contributions from scientists at GE’s Global Research Centre (Detroit), with input from aviation, power, and oil and gas departments, according to the GE Reports article.
Having built a prototype, Mitsui Seiki and GE are now working on multiple applications in which customers are willing to invest to develop manufacturing processes around the machine. Says the Mitsui Seiki vice president: “The key reality in all of this new technology [is that] it doesn’t matter whether it’s Blue Arc or cryogenic machining that came out a few years ago, or something else entirely, there need to be projects to start the thing off, to build con� dence,
[collect] empirical data and to gain market acceptance. The applications [for Blue Arc] now are coming forward rather rapidly.” The GE Reports article points out that interested companies may test out the machine by visiting GE’s Detroit site.
The Mitsui Seiki prototype machine that performs the Blue Arc process, visible in photographs with HW63-TD model markings in the GE Reports article, has been custom-built for the application on a “relatively standard” high performance 5-axis machining centre platform with standard spindles and components, according to Dolan, plus “a variety of unique features to satisfy the Blue Arc requirements.” Basic speci� cations provided show the machine to have a rigid prismatic slideway system, with axis strokes of 1,000 mm in X and 850 mm in Y and Z. Axis accelerations of up to 1.2 G support precision 5-axis contouring, while the direct-drive rotary axes (B and C) are driven at speeds of 60 and 90 rpm respectively. The machine also features Fanuc drives and Fanuc F30iM-B CNC unit.
Dolan adds that Mitsui Seiki’s strengths match the requirements of the job, partly because it has a history of dealing with cutting hard-to-machine materials, or cutting to tight tolerances. And the likely volume demands also suit the company, as he explains: “The number of units that would be anticipated to be sold in a short period of time is relatively small. Which suits a company like Mitsui very well; we are a largely custom-machine tool builder.”
The GE Reports article claims that the process requires a machine with a smaller footprint than an equivalent wholly-mechanical machine tool, wastes less material and generates fewer airborne contaminants.
That the Blue Arc process derives its power from electricity rather than physical force also affects the design of the machine; it needn’t be built entirely for brute force. Says Dolan: “The machine tool’s structural design can now be aimed at the semi-� nishing and � nishing operations of the process; you can now put the right spindles in, there is no compromise to be made.”
And he concludes: “This is new for the marketplace in the machining world. It’s going to change a lot for very many customers down the road.” ■
www.machinery.co.uk @MachineryTweets February 2017 15
LEAD FEATURE HIGH SPEED MACHINING INNOVATION FOR HARD ALLOYS
The Blue Arc electro-erosion process will drastically reduce roughing times in hard-to-machine alloys such as aero-engine parts, says inventor and developer GE. An adapted Mitsui Seiki machine tool has been delivered to GE’s aerospace global research centre near Detroit for customer trials. Will Dalrymple explains
14 February 2017 www.machinery.co.uk @MachineryTweets
Electric thinking
Below left: An electrode with coolant holes clearly visible
Below right: The Blue Arc process uses a modifi ed Mitsui Seiki machine
Below: Workpieces are held in an ‘electrifi ed’ fi xture; the spindle controls electrode movement. Left to right: before machining; during machining with disc-shaped electrode; after machining
Top: Tom Dolan, vice president, sales and marketing, Mitsui Seiki (USA)
Middle: Automatic loading of electrodes, which are sacrifi cial parts
GE’s Blue Arc process sees an electrode (below) ‘machine’ a fi xtured workpiece (left)
NEWS
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Water Jet Sweden’s €100,000 T-model waterjet pro� lerThe T-model waterjet pro� ler (right) has a � ying bridge construction, is designed to � t into a container and is easy to install and operate. https://is.gd/udawan
Entry-level 5-axis Matsuura has 10 palletsThe 10 by 130 mm diameter Capto C6 pallet, 90 tool, 15,000 rpm spindle 5-axis Matsuura MX-330 PC10 is targeted at manufacturers wanting reliable lights-out production. https://is.gd/nifi zu
‘Inspect’ for pro� le inspection with GapGun Pro Third Dimension’s Inspect software is designed to enable � exible analysis of a component’s pro� le, when used alongside Third Dimension’s GapGun Pro. https://is.gd/utumeh
Victor 3-axis P76 vertical machining centreVictor’s P76 is a 3-axis vertical machining centre offering axis travels of 760, 500 and 510 mm in X, Y and Z, respectively. https://is.gd/imobuw
DMG Mori CLX350 CNC latheThe CLX350 CNC lathe occupies less than 5 m2 but can turn components from bar of up to 51 mm diameter (65 mm optional), has a maximum turning diameter of 320 mm and Z-axis travel of 530 mm. https://is.gd/wosaqu
Starrett horizontal digital video projector The Starrett HDV500 digital video projector combines a large, � oor-standing, horizontal optical projector and a vision metrology system. https://is.gd/ovudoy
Sick AppSpace offers ecosystem for application solutions Sick AppSpace is a “unique open software platform for programmable sensors” that system integrators and OEMs can use to implement application solutions on Sick programmable devices. https://is.gd/tezamu
Omax “essentially-featured” GlobalMAX waterjet line GlobalMAX waterjets feature Omax software, space-saving table design and ef� cient
direct-drive pump technology, with value and durability as key priorities. https://is.gd/lebeku
Composite inspection system for Romer Absolute Arm A composite inspection system for the Romer Absolute Arm with Integrated Scanner (left) from Hexagon Manufacturing Intelligence avoids the need for a robot-based set-up. https://is.gd/owinow
Carbon � bre wheel hubs offer surface quality Krebs & Riedel composite carbon � bre wheel hubs from Advanced
Grinding Solutions are available to suite the existing K&R range of CBN and diamond wheels. They offer maximum strength and minimum weight. https://is.gd/xitutu
DAILY NEWS & PRODUCT UPDATES @ www.machinery.co.uk
8 May 2017 www.machinery.co.uk @MachineryTweets
A 7-axis Bumotec s191 linear CNC turn-mill centre (above) has been installed at the AMRC with Boeing to “develop revolutionary new machining processes in any material and for any sector”. https://is.gd/keceha
Master Abrasives’ facility in Daventry now has an eco 200U grinding machine up and running. The � rm, which is the sole UK and Eire agent for the Meister Abrasives Corporation, an international manufacturer of high precision industrial abrasive products, has been busy setting up a new showroom at its Daventry location. https://is.gd/ewarog
CNC machine tool and manufacturing solutions provider Engineering Technology Group (ETG) has appointed an applications and presales technical engineer. Steven Howes has more than 15 years’ experience as a CNC machine tool engineer and team leader. He has responsibility for the North of England region. https://is.gd/utamag
XYZ Machine Tools has appointed a new export sales director who will focus on developing the potential for XYZ’s range of ProtoTRAK-controlled mills, lathes and CNC turning and machining centres across Europe, Africa and the Middle East. Howard Bamforth has taken on the role. He brings 28 years’ experience in the machine tool business to the task.https://is.gd/wiyiku
The sales director of Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has retired. Nick White, who has served at the � rm for 28 years, ‘hung up his boots’ at the end of March. https://is.gd/adolel
Global machine tool manufacturer Yamazaki Mazak has appointed a new European group managing director. Richard Smith (below, middle) took over from Marcus Burton (left) in April and now has responsibility for all of Mazak’s operations in Europe, including the UK. https://is.gd/xibacu
Tooling supplier Walter GB has made two newly-created strategic staff appointments. Maria Martin has been appointed as the channel manager for the company’s distribution network, while Lorraine Daley has been appointed to the role of UK marketing for the Bromsgrove-based � rm. https://is.gd/felupe
Laser specialist MBA Engineering Systems, has appointed Adam Ball as its new commercial director. He joins the MBA team at the � rm’s Wetherby HQ, bringing 23 years’ engineering experience, of which 12 were been spent with Bystronic UK in various roles, concluding as sales support and applications manager.https://is.gd/rebemi
Germany’s volumetric error compensation expert Etalon (UK: Mantech Geometrics) is launching a world innovation for volumetric calibration of 3-axis measuring and machine tools at the Control exhibition this month. LineCal is aimed at manufacturers of compact multi-sensor measuring systems, CMMs and machine tools that want to volumetrically calibrate their products quickly and accurately before delivery. https://is.gd/okolib
The Mobility Division of global engineering and technology solutions leader Siemens is pioneering the use of Stratasys FDM 3D printing technology by producing customised � nal production parts for German transport services provider, Stadtwerke Ulm/Neu Ulm (SWU) Verkehr GmbH. For low volume production, Siemens Mobility can 3D print � nal tram parts in a matter of days, as compared to weeks. https://is.gd/isumim
Taiwan-headquartered Fair Friend Group (FFG) is acquiring Italian grinding manufacturers Meccanodora, Morara and Tacchella from IMT Spa, through its newly created af� liate company Grinding Technology Srl. https://is.gd/ukuwaq
HRH The Duke of York has of� cially opened the University of Shef� eld’s fully recon� gurable collaborative research facility, Factory 2050, at the Advanced Manufacturing Research Centre (AMRC). https://is.gd/pitimu
The three-year, £2.6 million TiFab programme, which has been backed by Innovate UK, has studied more than 170 titanium alloy structural airframe parts to assess their suitability for an advanced joining process that could offer annual raw material savings of around £9 million. https://is.gd/ecexuc
NT CADCAM has been the UK agent for Israeli software � rm Visual Factories and its Performance Improvement Manager software since the beginning of this
year. The new UK agent was present at the Factories of the Future event held in Manchester early last month (p19), where Machinery caught up with the founder and CEO of the two-year-old � rm, Matti Tiano (pictured, right). https://is.gd/xenumo
The University of Shef� eld’s AMRC has been named a ‘Supplier of the Year’ by the Boeing Company. The AMRC, which was co-founded with Boeing more than a decade ago, was honoured in the ‘Innovation’ category of the aerospace � rm’s annual Supplier of the Year awards, which were held on 12 April in Dallas, Texas. It’s the second time of winning for the AMRC. https://is.gd/canowa
Tamworth-based Press & Shear has concluded a sole agency agreement with Dutch machinery
manufacturer WEMO. The agreement covers the sales
and service of the Dutch operation’s sheet metalworking production lines in both the UK and Ireland.https://is.gd/ihixip
Lloyds Bank Commercial Banking is to
be the headline sponsor for MACH 2018, which will be held between 9 and 13 April 2018 at the NEC Birmingham. The event, which takes place every two years, brings together the best innovation and technology for a wide range of manufacturing sectors under one roof. It attracted more than 25,000 visitors in 2016. https://is.gd/ucogoy
News round-up Automation merger creates giantABB is set to acquire B&R, the largest independent provider focused on product- and software-based, open-architecture solutions for machine and factory automation worldwide.
Says the release: “Through the acquisition, ABB expands its leadership in industrial automation and will be uniquely positioned to seize growth opportunities resulting from the ‘Fourth Industrial Revolution’ [Industry 4.0].”
Both companies have complementary portfolios. ABB is a leading provider of solutions serving customers in utilities, industry and transport and infrastructure. B&R is a leading solution provider in the automation of machines and factories for industries such as plastics, packaging, food and beverage.
The joint commitment to open architecture increases customer choice and � exibility facilitating connectivity in increasingly
digitalised industries.With the acquisition, ABB will
expand its industrial automation offering by integrating B&R’s innovative programmable logic controls, industrial PCs and servo motion, as well as its software and solution suite.
ABB says it will offer its customers a uniquely comprehensive, open-architecture automation portfolio. The transaction is expected to close in summer 2017, subject to customary regulatory clearances. https://is.gd/aluxul
Manufacturing & Engineering 2017 will feature its strongest conference line-up yet when it opens in Newcastle this July. Visitors attending the event at the Metro Radio Arena from 5-6 July can hear from world-class speakers, including Liberty House Group, Hitachi Rail and the Scale-up Institute, focusing on opportunities for growth, the latest technology and inspiring case studies in the North East.
Education and knowledge sharing plays a pivotal role at Manufacturing & Engineering. Visitors can choose between keynote conference sessions and practical workshop seminars. https://is.gd/mojava
Product pick 10
Machinery● 100 years of serving the UK’s production engineering community● Read by decision makers and in� uencers● Published monthly with news and developments affecting your market● The tried-and-tested way to launch and build brand loyalty
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Machinery Events● One-day events and seminars, bringing thought leaders together● Platform to help shape the future of speci� c manufacturing sectors● PR and advertising opportunities via event previews and reviews● Direct contact with potential new business partners
Machinery/Machinery Classi� ed Ezines ● Individually targeted marketing messages● News and technology developments, delivered from the pages of Machinery
● Traf� c monitoring to enable effective reporting● Featured used machines for direct sales and stock promotion
Machinery Classi� ed ● Market-leading magazine for buying and selling used production equipment● Unique classi� cation of equipment makes what you’re looking for easy to � nd● Audited coverage of machine-tool-using sites
www.machineryclassi� ed.co.uk● Comprehensive Dealer Directory makes buying and selling used machines quick and easy● Continually updated machines for sale by type, brand and attributes● Optimised search for content and machines● Accessed by more than 17,000 unique users per month
Editorial Excellence
Helping UK production engineers make things more ef� ciently, to higher quality levels or via methods that they had not previously thought of is Machinery’s core focus, achieved through a mix of technology and business news plus features
every month, with this supported by its always-available website.Machinery’s editors visit numerous factories every year, bringing you exclusive content
about UK engineering companies, as well as UK and overseas technology suppliers. They seek out the stories that others simply do not pursue, spot or cover in any great depth. These often provide the basis for our unique cover stories – one of Machinery’s key differentiators and one that gets the magazine noticed on crowded desktops, then picked up and read.
In 2017, for example, Machinery’s cover stories, supported by high quality images, included: a report on the Advanced Forming Research Centre’s work that seeks more predicable machining of forged parts; the machining of challenging materials using an electrical method offering high volume metal removal; Jaguar Land Rover’s quality-driven process improvement initiative; Liberty Group’s vertically integrated electricity-generation to steel-machining operation; the potential for greater use of magnesium in aerospace; AMRC Castings’ unique titanium casting facility; Mazak’s next-generation laser pro� ling development; and cost-saving linear friction welding of aerospace components.
Such articles are those that Machinery’s audience can identify with, learn from or just plain be entertained by. They bring leading examples of modern manufacturing to your desktop on a monthly basis.
And these articles are in addition to the magazine’s strong editorial programme-driven content, through which its editors keep readers up to date with various key technology areas and industry sectors. These features are written with pace, conveying information in a concise, understandable fashion; because we know readers’ time is precious.
Now in its second century of publication, Machinery and the market it serves have changed and will continue to do so. But a sense of enquiry, attention to detail and high standards remain a constant for the magazine’s editors.
A publication that gets read is no accident; that Machinery is the UK’s market-leading production engineering journal is no accident. Our editors understand that and work towards delivering a monthly read that will see both continue into the future.
Editorial
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18 April 2017 www.machinery.co.uk @MachineryTweets
transport); and £400 million of venture capital from the British Business Bank.
He exampled the government and industry working together to develop a strong UK position in battery technology as part of positioning Britain as a world leader in electric and connected and autonomous vehicle technology (the ‘Vehicle Technology and Aviation Bill’ that is making its way through parliament is part of this). Simon Evans, director, manufacturing and materials, Innovate UK, also instanced battery development and manufacture, highlighting the budget announcement of £270 million for UK companies to develop “disruptive technologies”, including driverless and connected cars, as well as electric vehicle battery technology.
But “what makes this industrial strategy different?” asked Lord rhetorically, noting that historian Lord Peter Hennessey has counted 18 such policies since Anthony Eden (PM 1955 to 1957). He said he would not “traduce or criticise previous strategies”, adding that Lord Mandelson of the last Labour government and Vince Cable of the previous coalition government had led good efforts. But this strategy is “genuinely across government” led by a Cabinet committee chaired by the Prime Minister, “a very strong Prime Minister with a handle on this”; that, he said, is quite different to previous efforts of
the past. Second, it is “long-term and ambitious” with the government “asking for ideas”. Third, it is about the whole economy; it includes manufacturing and engineering, but is not just about them. Fourth, it brings regional and industrial policy together, where they have previously been separate. But the green paper has been criticised by a BEIS committee, as already noted. And, as it happens, it had been the chair of that very committee, Iain Wright, who had initially been scheduled to speak, not Lord.
HIGH VALUE MANUFACTURINGAlso speaking from the government side, Innovate UK’s Evans talked about research funding, how its management was to be improved, and about the High Value Manufacturing (HVM) Catapult’s success. As of April 2018, Innovate UK, the seven research councils and the Higher Education Funding Council for England will be folded into UK Research and Innovation (UKRI). The case for this was set out last June (https://is.gd/vixuzu) – this “offers an opportunity to strengthen the strategic approach to future challenges and maximise value from government’s investment of over £6 billion per annum in research and innovation”. (A recent House of Commons’ Select Committee [https://is.gd/ebamub] said that UKRI “should take a pivotal role in developing
and sharing good practice in commercialising university research”.) And on the ‘industrial challenge’ fund, Evans said that manufacturers had been the largest constituent at recent events.
Moving onto the HVM Catapult, whose seven centres take basic research and then work with industry to bridge ‘the valley of death’ to bring new products/processes to industrial readiness, Evans cited two recent successes that atest to the drawing power of such facilities, speci� cally the Advanced Manufacturing Research Centre with Boeing (AMRC) and the McLaren and Boeing wins. The McLaren move relates to reshored Austrian activity linked to composite car part production at a new facility next to the AMRC (https://is.gd/uverij); the other is a new, multimillion-pound production facility, also to be built alongside the AMRC and the � rst Boeing manufacturing facility in Europe (https://is.gd/ujudur).
Returning to the strategy more generally, four similar points of critique were made by: EEF chief economist Lee Hopley; the CBI’s Emma Roberts, head of industrial strategy; Tim Frenneaux, deputy chief operating of� cer, York, North Yorkshire and East Riding Local Enterprise Partnership (LEP); and Professor Simon Collinson, chair, Chartered Association of Business Schools, and deputy pro-vice-chancellor for regional engagement,
The government issued its green paper industrial strategy consultation document (https://is.gd/simare) on
23 January, with a response deadline of 17 April 2017 (https://is.gd/vateda). The paper sets out 38 questions that people might answer, by way of feedback.
In our December issue (https://is.gd/koduro), we ran over industrial strategy from the ‘60s on up and took in what was being said by organisations and politicians, following Prime Minister Theresa May’s announcement of such a strategy ahead of her � rst cabinet meeting last August. Since then, there have been of� cial meetings up and down the country to garner input, both before and after the green paper’s publication.
The 132-page industrial strategy green paper says that government’s approach will be based on 10 pillars: investing in science, research and innovation; upgrading infrastructure; improving procurement; delivering affordable energy and clean growth; driving growth across the country; developing skills; supporting businesses to start and grow; encouraging trade and inward investment; cultivating world-leading sectors; and creating the right institutions to bring together sectors and places.
There has been less than fulsome feedback from the Business, Energy and Industrial Strategy (BEIS) Committee on that green paper and related action so far. It said in March: “The Prime Minister’s talk of a proper industrial strategy, with more active intervention into the activities of the economy, marks a signi� cant shift from the approach taken by previous governments of the last 40 years, but so far there’s little evidence of the strategic framework or the co-ordination across government necessary to achieve ‘an economy that works for all’.”
UNCOMMITTED COMMITTEEAdded Iain Wright, MP, committee chair: “An industrial strategy can only begin to help tackle these issues if it recognises that an economy can have a direction of travel, has a vision and is ambitious, and [is] co-ordinated right across government. As a committee, we are concerned that with government announcements the approach seems to be ‘business as usual’ and a silo-based approach in Whitehall, which will not achieve the step-change the Prime Minister aspires to and that, as a result, the industrial strategy will fall short in providing a clear framework for industries and businesses to deliver future success.
The government must be bold, ambitious and visionary in
developing its industrial strategy to
ensure the
sectoral and regional balancing to which it rightly aspires is achieved.” (Full report: https://is.gd/cetane.)
At the Westminster Forum event of last month – Priorities for shaping the UK’s Industrial Strategy – Tim Lord, director of industrial strategy at BEIS, accepted the possibility of multiple interpretations of the term ‘industrial strategy’, pointing out that the OECD has 31 de� nitions, adding: “And six months in, we are probably in the process of creating a 32nd.” The industrial strategy green paper was, he said, a mixture of consultation (green) and policy actions (white), while adding that the strategy will not be set in stone after Royal Assent.
Overall, it is about “improving living standards and economic growth by increasing productivity and driving growth across the whole country”. To achieve that, he said that there are three key challenges now and into the future: building on strengths, extending excellence; closing the gap between the performance of the best companies and the rest; making the UK the best place to start and grow and business.
Of actions already taken by government that fall within the developing strategy, he cited the extra £4.7 billion of R&D funding by 2021 (part of that will fund a new Industrial Strategy Challenge Fund that will direct some of that investment to scienti� c research and the development of a number of priority technologies); £500 million backing for technical education (see p7); the £23 million infrastructure fund (5G,
www.machinery.co.uk @MachineryTweets April 2017 19
Jaguar Land Rover’s I-Pace electric car will, in 2018, “bring thrilling Jaguar
performance to electric vehicles”. Electric vehicle technology is being heavily promoted and supported by
government, as the event underlined
The event, ‘Priorities for shaping the UK’s Industrial Strategy’, was
held at The Institution of Mechanical Engineers, London, in March
A strategy for all
INDUSTRIAL STRATEGY LONDON EVENT HEARS FROM INDUSTRY ORGANISATIONS, ACADEMIA & MORE
Last month, Andrew Allcock attended a meeting in London: ‘Priorities for shaping the UK’s Industrial Strategy’. Having a manufacturing theme, he picks out some so far less well-aired points
18
The government issued its green paper industrial strategy consultation document (https://is.gd/simare
23 January, with a response deadline of 17 April 2017 (https://is.gd/vatedaThe paper sets out 38 questions that people might answer, by way of feedback.
In our December issue (https://is.gd/koduro), we ran over industrial strategy from the ‘60s on up and took in what was being said by organisations and politicians, following Prime Minister Theresa May’s announcement of such a strategy ahead of her � rst cabinet meeting last August. Since then, there have been of� cial meetings up and down the country to garner input, both before and after the green paper’s publication.
The 132-page industrial strategy green paper says that government’s approach will be based on 10 pillars: investing in science, research and innovation; upgrading infrastructure; improving procurement; delivering affordable energy and clean growth; driving growth across the country; developing skills; supporting businesses to start and grow; encouraging trade and inward investment; cultivating world-leading sectors; investment; cultivating world-leading sectors; and creating the right institutions to bring together sectors and places.
A strategyA strategyALast month, Andrew Allcock attended a meeting in London: ‘Priorities for shaping the UK’s Industrial Strategy’. Having a manufacturing theme, he picks out some so far less well-aired points
www.machinery.co.uk @MachineryTweets April 2017 15
LEAD FEATURE LIBERTY HOUSE GROUP’S INTEGRATED UK STEELMAKING & SUPPLY CHAIN AMBITION
Driven by a new vision of integrated British steelmaking, commodities trader Sanjeev Gupta has, in the last few years, built an industrial conglomerate that aims to underpin British manufacturing post-Brexit, starting with the automotive sector. Will Dalrymple reports
Liberty House Group operations span hot-rolled coil to car parts, and beyond
A £10 million automotive centre of excellence in Leamington, announced in February, is just the latest investment for steel conglomerate Liberty
House Group (LHG) that, with other family businesses, has spent 50 times that much in the UK since 2015.
The 50,000 ft² centre opening next year, being built to “accelerate its automotive sector growth” is located alongside Liberty Vehicle Technologies, which, as its name suggests, manufactures brakes and automotive parts for relatively low-volume vehicle markets, including motorsport (NASCAR), London Taxis, US yellow school buses and the Warrior Land Rover. No doubt it will work closely with Daventry-based motorsport mechatronics fi rm Shiftec (www.shiftec.com), LHG’s newest acquisition, also announced in February.
But LHG’s automotive offerings aren’t all like this. Far higher part production volumes are produced nearby at the 33,000 m² plant of Liberty Pressing Solutions (formerly Covpress) in Coventry, offi cially inaugurated in late February. The 750-employee presswork fi rm makes body-in-white and trim components, and is a Tier 1 supplier to Jaguar Land Rover (JLR), Renault and GM.
Douglas Dawson, Liberty Engineering Group CEO, says the vehicle technologies businesses and car parts production businesses work together to mutual benefi t; these kind of synergies are a LHG speciality. He told Machinery: “In particular, the vehicle technologies business is the ‘calling card’ for more mainstream automotive contracts. It shows the world that we’re serious; we’re not just a capacity-driven business, we’re innovative, there is more about us.”
The automotive centre of excellence marks a shift in strategy for the company, as it is LHG’s fi rst development project uniting multiple businesses. According to Dawson, automotive contracts make up “quite a large part” of the activities of Liberty Engineering Group. It has seven divisions, each of which starts with the word ‘Liberty’: Vehicle Technologies and Pressing Solutions (both mentioned above); Vehicle Products; Tubular Solutions;
14 April 2017 www.machinery.co.uk @MachineryTweets
Distribution; Performance Steels (a West Bromwich steel strip manufacturer); and Forging Europe of Poland.
Most of these businesses were inherited in 2015, through the acquisition of varied metalworking producer Caparo plc. In December 2015, referring to those operations, executive chairman of LHG Sanjeev Gupta said: “Despite current diffi culties, advanced engineering can create enormous value for the UK economy, and I’m convinced that, based on the right business model, operations like these have strong growth potential in the UK and across various markets internationally where Liberty is present.”
Last month, the company also hosted the fi rst meeting of the Lochaber Delivery Group, a public-private regional development panel supporting another much larger automotive-facing project: a £120 million initiative to build a new-build alloy wheel casting facility at the Fort William, Scotland, aluminium smelter that was bought by LHG last year. That facility, Britain’s only operational aluminium plant, has a production capacity of nearly 50,000 tonnes/year, and LHG plans to at least double that through a factory optimisation programme.
The planned factory, Britain’s fi rst alloy wheel casting plant, would receive molten aluminium from the smelter and pour it directly into casting pots, saving the energy that would be required to re-melt alloy needed to start wheel casting elsewhere. Factory capacity is envisaged as reaching up to two million units per year, consuming 20,000 tonnes of aluminium, Dawson says.
This project is a microcosm of LHG’s vision of uniting metalmaking and metalworking in an integrated package, each aspect benefi ting from the other: the smelter gets a ready customer; the wheel plant, a molten material supplier. And the supply chain may grow even tighter than that; a portion of future aluminium might be processed into sheet for lightweight automotive body parts at its Coventry pressing business, perhaps increasing the amount of aluminium processed there, currently 5,000 tonnes, to parity with steel production at 65,000 tonnes per year, further driving the smelting operation.
The smelter also came with most of the electricity to operate it, in the form of the Fort William and Kinlochleven hydro power plants (85 MW capacity). These operations provide low-cost electricity that is essential to the process and to the smelting unit’s economic competitiveness. In addition, last month the site inaugurated a new £10 million biodiesel power plant, 20 MW capacity, enabling the plant to operate at full capacity even when dam waters run low.
Gupta’s vision, dubbed ‘Greenmetal’ or ‘Greensteel’, goes beyond the automotive supply chain, beyond engineering companies and beyond steel. It aims to do no less than rebuild the UK’s metals industry, and not by buying and
refi ring blast furnaces such as at SSI’s Teeside Steelworks in Redcar, shut in 2015. Says Dawson: “We don’t have any iron ore or coking coal in this country. So our steelmaking ambitions are almost fl awed before they start, because the raw materials are imported and subject to global capacity demand and global currency fl uctuations.”
Instead, LHG’s steelmaking vision is based on a process that is new to the UK: melting recycled scrap steel in electric-arc furnaces. LHG quotes an (unnamed) Cambridge University report that found that 70% of UK scrap is exported, and that the amount of scrap produced will rise from 10 to 20 million tonnes a year during the next decade. This scrap becomes the raw material feeding this new type of UK steelmaking business, following the successful model used by US steelmakers Nucor and Steel Dynamics, for example.
Last summer, during the run-up to a bid to acquire all of the shares of Tata Steel (the effort fell through in July), Gupta recorded a speech in a to-camera video. He said: “Steel is right at the heart of the manufacturing ecosystem, so if we can’t make steel competitively here, then we’re far less likely to hold onto industries that make products from this iconic material. But the reverse is also true. If we can fi nd a way to make steel profi tably in the UK, we can not only preserve and increase the number of jobs in the steel
Liberty Industries Group operations(Liberty Steel, Liberty Aluminium, Liberty Engineering)
● Primary metals production
● Rolling mills
● Downsteam products (tube, bar)
● Distribution
● Engineered products
● Technology business
Vision of steelSanjeev Gupta, left, and Douglas Dawson with a T1 Evo hypercar model – an update of the Caparo T1 – that will include products from many group businesses
Gupta speaks with Nick Hurd, Minister of State for Business, Energy & Industrial Strategy, at Liberty Pressing Solutions
EdinburghGlasgowGlasgow
Fort William
BelfastNewcastle
Manchester
BirminghamBirmingham
Leeds
Aberdeen
Norwich
BristolLondon
Sheerness
Southampton
Cardiff
Plymouth
Swansea
•
AdobeStock
Alam
y
Month
January Machining Sawing & steelworking Grinding, honing Quality & metrology ● Aerospace ● MACH (9-13 April) First Preview ● METAV (20-24 Feb) Preview & surface � nishing ● Southern Manufacturing (6-8 Feb) Preview
February Turning Punch, pro� le, bend Workholding, Coolants ● Subcontracting ● MACH (9-13 April) Second Preview & form accessories & barfeeds & cutting oils ● Tool, mould & die making
March EDM & ECM Additive manufacturing Tooling Industry 4.0 & CADCAM ● Medical Aerospace ● MACH (9-13 April) Third Preview automation & production IT ● Heavy engineering
April Machining centres Composites machining Deep hole drilling Quality & metrology Cleaning & degreasing ● Subcontracting ● MACH (9-13 April) Show Issue ● Energy ● Control, Stuttgart, (24-27 April) Preview
May Turning Grinding, honing Part marking ● Motorsport Tooling, workholding ● MENE, Newcastle (4-6 July) First Preview & surface � nishing & traceability & accessories ● MACH (9-13 April) Review
June Sawing & steelworking Punch, pro� le Tooling CADCAM ● Subcontracting Launched at MACH ● MENE, Newcastle (4-6 July) Second Preview bend & form ● Farnborough International (16-22 July) Preview
July Machining centres EDM & ECM Additive manufacturing Workholding, Quality & metrology ● Aerospace Energy accessories & barfeeds
August Turning Composites machining Micro-machining Cleaning & ● Subcontracting Industry 4.0 & ● AMB (18-22 Sept) Preview degreasing automation September Grinding, honing Deep hole drilling Tooling Part marking ● Heavy engineering Five-axis machining ● EuroBLECH (23-26 Oct) Preview & surface � nishing & traceability ● Tool, mould & die making
October Machining centres Punch, pro� le, Deep hole drilling Quality & metrology ● Subcontracting Aerospace ● Formnext (13-16 Nov) Preview bend & form ● Medical ● Parts2Clean (23-25 October) Preview
November Turning EDM & ECM Additive manufacturing Workholding, Industry 4.0 & ● Energy CADCAM & ● IMTS (10-15 Sept) Review accessories & barfeeds automation production IT
December Grinding, honing Sawing & steelworking Coolants & cutting oils Tooling ● Subcontracting Speaking of success ● Autosport Engineering (Jan 2019) Preview & surface � nishing ● Motorsport ● EuroBLECH (23-26 Oct) Review
Production Processes Production Support Sectors Special Reports
Editorial Programme 2018
2018 editorial programme
www.machinery.co.uk
Exhibition Previews/Reviews
1 - 19 16,311 2,616 4,174 4,041 78,625 20,609 6,610 4,852 5,812
20 - 49 7,879 963 2,326 2,251 55,085 19,218 4,687 2,445 3,151
50 - 99 3,742 388 1,068 1,039 33,380 10,684 2,699 1,117 1,405
100 - 199 2,312 209 648 623 23,486 7,817 2,238 689 956
200 - 499 1,784 155 458 446 22,096 9,819 2,358 495 803
500 - 999 511 40 150 146 11,837 5,713 2,105 158 462
1,000+ 265 5 88 85 12,754 4,976 4,452 89 411
TOTAL 32,804 4,376 8,912 8,631 237,263 78,836 25,149 9,845 13,000
No. Employees
No. Sites
Non- Intensive Machine
Tool Users
All Intensive Machine
Tool Users
Total Machine
Tools
IntensiveCNC
Machine Tool Users
Total CNC Machine
Tools
SitesReceivingMachinery
Production Engineers
Total Copies
10,157 2,036 5,504 5,340 130,135 45,009 11,233 6,311 7,889
9,099 1,974 3,155 3,053 99,132 32,277 12,156 3,211 4,686
13,548 366 253 238 7,996 1,550 1,760 323 425
32,804 4,376 8,912 8,631 237,263 78,836 25,149 9,845 13,000
Machinery’s terms of control accurately target the magazine’s circulation to reach individuals in production engineering and
management in UK sites using machine tools or outsourcing machine tool work
Site Activity/Type
No. Sites Non Intensive Machine
Tool Users
AllIntensive Machine
Tool Users
Intensive CNC
Machine Tool Users
Total Machine
Tools
Total CNC Machine
Tools
Production Engineers
SitesReceivingMachinery
Total Copies
Readers by site activity and machine tool usage
Circulation universe summary
Distribution by job function Distribution of readership by key industrial sectors
Daily Budget Daily Budget Weekly Budget Monthly Budget Total Annual Budget
Expenditure £13,698,367 £96,152,000 £416,658,667 £4,999,904,000
Total spend authority of Machinery’s readers over 12 months
ABC Average Net Circulation 14,794 (Jan-Dec 2016)Note: Some readers have multiple job functions and responsibilities
Subcontract Manufacturers
OEMs
Non-OEM/Non-Manufacturing (Design/Educational sites)
0%
Medical
Oil/Gas/Energy
FMCG
Defence
Automotive
Aerospace
10%5% 15% 20% 25% 30%
17%
4%
13%
14%
19%
11%
0%
Production/assembly& finishing
Productionmanagement
Production engineering/process control/
Control & Instrumentation
Quality/test/calibration
Tooling
Machine tool purchasing
20% 40% 60% 80% 100%
76%
63%
73%
65%
25%
56%
63%56%
Circulation
www.machinery.co.uk
Machinery’s unrivalled circulation
Not all magazine circulations are the same – even if claimed reader numbers look similar. And not all readers are the same. For your marketing message to work effectively, it has to reach those individuals who can in� uence a company’s
investment decisions, specify what’s required, select the potential suppliers or sign off purchase orders.
In some organisations that might all come down to one person; in another, it could be a whole team. Either way, in order to reach the right people, publishers need to know, so that your marketing is as effective as possible.
Only a structured, thorough and continuous investment in circulation research enables a publisher to identify appropriate readers precisely. Machinery does target its readers precisely and its circulation claims are endorsed by a full ABC audit each year.
Machinery’s circulation is a subset of MA Business’s UK manufacturing universe data, which can identify individuals not just by job titles but also by their important primary and secondary functions – such as their in� uence on purchasing decisions. The MA Business database identi� es sites known to use machine tools, how many machines are installed and what types are being used, by sector, company size and geographic location.
Machinery’s circulation de� nes the UK’s machine tool buying universe. As a result, your marketing reaches the right people. No wasted effort, no time-wasters. No false claims.
Machinery Classifi edBuying power
Machinery Classi� ed
www.machineryclassi� ed.co.uk
Machinery Classi� ed is the � rst-choice magazine for those engaged in the buying or selling of used production equipment in the UK.
Proving itself time and again, with its rotational circulation reaching a total audience of 11,150 readers and its fully researched coverage of all UK used machine tool merchants and suppliers, Machinery Classi� ed offers the best possible route to the UK’s machine tool buying universe, bar none!
Whether you like to use print advertising or online marketing to buy and sell, Machinery Classi� ed now offers even more ways to help you achieve your aims. The magazine is published twice monthly, with an electronic newsletter sent every week to make sure no opportunity to promote your machines is missed. This is then backed up with Machinery Classi� ed’s highly optimised website, which regularly takes in equipment updates to ensure that it’s always the latest machines that are being promoted.
To keep the traf� c coming and the visibility high, Machinery Classi� ed is distributed once a month with Machinery magazine, which boasts market-leading editorial content. Two weeks later, Machinery Classi� ed goes direct to the machine tool-using universe.
Both issues promote your name and your machines, and drive readers to the website.We’ve got all the bases covered to ensure that your machines have the very best chance of being seen by the people who have the authority to buy and sell.
“Machining Solutions is an e-marketing business, so has tended to steer clear of traditional adverts in the trade magazines. We decided, however, to gauge results compared to our normal means of promotion. We placed ads in several mainstream journals, the one which achieved the most enquiries and resulted in a fast sale was Machinery Classi� ed. They have a professional team that deliver results. We will certainly use them again for all our magazine adverts. Well Done.”
Mr Steve King – Machining Solutions
www.machineryclassified.co.uk
THE INDUSTRY’S NO. 1 PRODUCTION EQUIPMENT JOURNAL FEBRUARY 2017 ISSUE 1
001_MYC_FEB01 FRONT COVER.qxp 26/01/2017 13:49 Page 1
30
October 2015, issue 1 - Machinery Classified
0860 > Lathes, Oil Country, Hollow Spindlewww.machineryclassified.co.uk
[1] 400mm [3] 1250mm COLCHESTER COMBI 2000 CNClathe, gap bed, Fanuc 210i-T, 54mm bore, steady, 3 and 4 jawchucks, speeds to 2500rpm, QCTP, coolant, 400 x 1250mmcapacity (20285) £12,950. Fax: 0161 343 1347Email: [email protected] Tel: 0161 330 4242
www.newcentury.co.uk
[1] 400mm [3] 1250mm Harrison Alpha 400 Harrison Alpha400 Plus C/w chucks & steady New 1998. Fanuc GE control.£9750. Email: [email protected] wTel: 0114 279 7619 www.philgeesinmachinery.co.uk
Citizen M20 - III 2001, Iemca Boss 432R, Absolent ODF1000S& Cool Blaster, Parts Catcher, 3 Treble Static Drill/Boring Holders,2 x Double Turning Toolholders, 1 driven tool holder.Email: [email protected] wTel: 01444 245414 www.stevenmooneymachinery.co.uk
[1] 230mm [2] 203mm [3] 231mm DOOSAN Puma ModelTT1800SY (28036) 8 Axis CNC Slant Bed Lathe with SubSpindle, Twin Turrets, Driven Tooling & Fanuc 18iTB Control.Email: [email protected] Tel: 0161 633 8880
www.gmmachinery.com
[1] 330mm Harrison Alpha 330 Plus Straight Bed TeachLathe (11441) MFD 1997, Swing Over Bed 330mm, SwingOver Saddle 210mm, Distance Between Centres 1000mm. Fax:01642 227740 Email: [email protected] wTel: 01642 227722
www.nmteng.com
[1] 850mm [2] 3000mm [3] 250mm Binns & Berry Data90 x 3,000mm CNC Oil Country Lathe with Twin Chucks & Fagor8030 TC Control. Swing over cross slide 750mm. Sauter 4-waytoolpost. Spindle bore. Spindle speeds to 550 rpm (inf. var). Mainmotor 37 kW. Machine fitted with 2 x 750mm dia 4 jaw chucks. 2 x Fixed Steadies. Travelling Steady. Sliding guard. (28046).Email: [email protected] Tel: 0161 633 8880
www.gmmachinery.com
[1] 400mm Colchester Combi 2000 (F2738) CNC Gap BedTeach Lathe, MFD 1998, Fanuc 210i/T CNC Control, swing overbed 400mm, swing over saddle 245mm, swing in gap 585mm,maximum distance between centres 1250mm. Fax: 01642 227740Email: [email protected] wTel: 01642 227722
www.nmteng.com
[1] 1200mm [2] 3000mm [3] 360mm GURUTZPE MODELA -1600 Centre height 610 mm. Swing over cross slide 800 mm.Spindle speeds 0 – 480 rpm. Spindle nose A-20. Front bearing dia.430 mm. Maximum workpiece weight 10,000 kgs. Headstockpower 39/48 kW. Twin 4 jaw chucks (Front 790mm Rear 700mm).Powered tailstock (Brand New). 3 point roller steady 50mm –500mm dia. Hi/Low range Gearbox. Fagor CNC8055 Control. Yearof manufacture 2008. Under power in our warehouse now. (28039)Email: [email protected] Tel: 0161 633 8880
www.gmmachinery.com
[1] 850mm [2] 3000mm [3] 368mm BINNS & BERRY CNCOil Country Lathe. FANUC OT / Capacity: 850 x 3000mm.Spindle Bore: 368mm (ST2405).Email: [email protected] Tel: 01382 200797 www.taysidemachinery.co.uk
METROL
Tel No: 01932 830492Email: [email protected]: www.cncsystemsltd.co.uk
METROL
Supplied by CNC Systems Ltd UK and European distributors
High accuracy sensorsUsed on CNC lathes,Machining centres and Grinders
[1] 250mm [3] 150mm MORI SEIKI HITECH CS250Y New2003, 5 axis, live tooling, C axis, Y axis, Ewab loading andunloading, swarf con, tooling, well tooled, Seicos 21L, 250 x150mm capacity (20324) £39,950. Fax: 0161 343 1347Email: [email protected] Tel: 0161 330 4242
www.newcentury.co.uk
CNC
Lathes, Sliding Head0872
[1] Swing Over Bed [2] Distance Between Centres[3] Spindle Bore
Lathes, Oil Country, Hollow Spindle0860
012-42_MYC_OCT01.qxp 05/10/2015 15:08 Page 30
Machinery Classified - October 2015, issue 1
31
< 0910
www.machineryclassified.co.ukMachining/Milling Centres, Horizontal
[1] 23" [2] 10.312" [3] 66" WARD 10C Prelector LargeBore (1978) 262mm Spindle bore, 3 & 4 Jaw chucks, Taperturning, Very Good Conditon.Email: [email protected] Tel: 01564 773351 www.ronthompsonmachinery.co.uk
Hüller Hille NBH 230R Twin Pallet Horizontal MachiningCentre, 2006, Siemens Sinumerik 840D, Pallet 800mm x 630mm,50DV/Cat spindle, 150 station ATC.Email: [email protected] wTel: 01444 245414 www.stevenmooneymachinery.co.uk
[1] 965mm [2] 450mm [3] 630mm IMA MB-20 CNCMilling Machine S/N 1999981201, Anilam 3300M CNCControl. X-Axis = 965, Y-Axis = 450, Z-Axis = 630 mm. PowerDraw Bar. Spindle Speeds 60-3600 rpm. Spindle Taper ISO 40.Table Size 1370 x 400 mm. This Machine Has Had Very Little UseFrom New And Is In Superb Condition. #77841. Price £7,950. Fax:01384 633946 Email: [email protected] wTel: 01384 633968 Web: stores.ebay.co.uk/Jet-Machinery-The-Engs-Merchants
[1] 788mm [2] 262mm [3] 1600mm Ward 10X TurretLathe (F1749), Cross Sliding Large Spindle Bore CominationTurret Lathe, Swing Over Bed: 788mm Swing Over Saddle: SpindleBore: 262mm Chuck To Turret Face: 1600mm Fax: 01642 227740Email: [email protected] wTel: 01642 227722
www.nmteng.com
Metba 3 Axis CNC Bed Type Milling Machine (F2378),Table 1870 x 600mm, Heidenhain 355 Control. Fax: 01642 227740Email: [email protected] wTel: 01642 227722
www.nmteng.com
Makino Model A77 Twin Pallet Horizontal MachiningCentre 1999, Makino (Fanuc) Professional 3 Control. Pallets630mm x 630mm, BT 50,90 station ATC.Email: [email protected] wTel: 01444 245414 www.stevenmooneymachinery.co.uk
[1] 915mm [2] 150mm Herbert 12B Cross Sliding TurretLathe (F2585), Swing Over Bed 915mm, Max Distance Spindleto Turret Face 1010mm, Spindle Bore 150mm. Fax: 01642 227740Email: [email protected] wTel: 01642 227722
www.nmteng.com
Hebert 14/45 Combination Turret Lathe. Capacity: 1230 x2300mm. (ST2370). Email: [email protected] Tel: 01382 200797 www.taysidemachinery.com
[1] 830mm [3] 3090mm HERBERT 12B Long BedCombination Turret Lathe. Capacity: 830mm x 3090mm.(ST2409). Email: [email protected] Tel: 01382 200797 www.taysidemachinery.co.uk
Machine Ref: 911. Electrics: 380/440volts 3 Phase. 4 WayMachine Ref: 911. Electrics: 380/440volts 3 Phase. 4 Way ToolPost. Turret Tooling. 2 5/8" spindle bore Speeds 27 - 1100 rpm .Swing over Cross slide 15". Swing over top of Cross slide9 1/2".Swing over covers 16".# Admits between spindle and hex turret 42".Fax: 0121 565 2438. Email: [email protected]: 0121 555 6392 www.stevensmachinetools.co.uk
J Hodson Machine ToolsContact us for a free quote
Cincinnati Machine Tool Spares & Parts● a wide range of CNC Cincinnati Machines Spares & Parts
● New Parts for Cincinnati Machine Tools● Parts are ex-stock & available for collection/next day deliveryJohn Hodson Service Exchange offers:● Service Exchange & Reconditioned Units● Next Day Delivery (return old unit within 10 working days)Cincinnati Machine Service● Breakdown Service ● Installation & Commissioning● Renishaw Ballbar Test ● Motor & Drive Repairs● PM Contracts
Contact John Hodson:Ê07976 553050ÊÜÜÜ°V��V���>Ì�«>ÀÌðV�°Õ�
Non-CNC
[1] X Axis Travel [2] Y Axis Travel [3] Z Axis Travel[4] Type
Machining/Milling Centres, Horizontal0910
[1] Swing Over Bed [2] Spindle Bore[3] Turning Length
Lathes, Turret0875
www..co.uk
012-42_MYC_OCT01.qxp 02/10/2015 11:21 Page 31
Rate Cards
www.machinery.co.uk/www.machineryclassi� ed.co.uk
Rate cards
Machinery 2018 Rate Card
Display Advertising x1 x6 x12Full Page £2,835 £2,415 £1,995Half Page £1,680 £1,470 £1,210Quarter Page £1,000 £895 £790
Products & Services Panel Advertising£33 per single column cm
InsertsSingle sheet 10g or less = £1,890Double sheet 20g or less = £2,625
Online Advertising www.machinery.co.uk Banners/Tile Adverts from £840 per monthVideos and other rich media options from £1,050 per month
Online Buyers’ GuideEnhanced Supplier Record Card = £1,000 per annumEnhanced Supplier Record Card with Product Spotlight = £1,200
Company-speci� c e-shot to full ezine circulationE-shot £800
EzineBanners £500 per issueButton £250 per issueVideo of the Week £600 per issueSponsored News £630 per issue
Machinery Ad Sizes (height x width)
Half Double Page SpreadBleed 140 x 426mmTrim 137 x 420mmType Area 124 x 388mm
Double Page SpreadBleed 292 x 426mmTrim 286 x 420mmType Area 254 x 388mm
Page SizeBleed 292 x 216mmTrim 286 x 210mmType Area 254 x 178mm
Half HorizontalBleed 140 x 216mmTrim 137 x 210mmType Area 124 x 178mm
Half VerticalBleed 292 x 103mmTrim 286 x 100mmType Area 254 x 86mm
Quarter StandardType Area 124 x 86mm
Quarter HorizontalType Area 65 x 178mm
Online Leaderboard 728 x 90 pixelsBanner 468 x 60 pixelsLarge message panel 300 x 200 pixelsSmall message panel 300 x 100 pixels
Machinery Classi� ed 2018 Rate Card
Classi� ed AdvertisingPer line per issue x1 x4 x12 x24 Standard Listing £7.50 £6.50 £5.75 £5.25Bold Listing £10.00 £8.50 £8.00 £6.75Ruled Bold Listing £11.00 £9.50 £9.00 £7.75Photo Listing £70.00 £65.00 £57.50 £52.50Panel (per col cm) £10.50 £9.00 £8.50 £7.50 Display Advertising
Per issue x1 x4 x12 x24 Full Page £1,600 £1,400 £1,200 £950Half Page £1,100 £1,050 £900 £650Quarter Page £650 £575 £475 £325Machine of the Week £125 £115 £105 £95 Covers x1 x4 x12 x24
Outside Front £2,300 £2,100 £1,750 £1,400Inside Front £2,200 £2,000 £1,700 £1,150Outside Back £2,300 £2,100 £1,700 £1,400
Online Advertising www.machineryclassi� ed.co.uk Photo Listing £100 per two weeks Video £240 per month Auction Listing £200 per week Enhanced Supplier Record Card £1,000 per year Banners / Tile Adverts from £800 per month Machine of the Week £100 per week (min two weeks)
Ezine (Newsletters) Weekly newsletter sent to Machinery’s online circulation and ‘Buying Now’ readers. Banners £300 Button £175 Video of the Week £300 Sponsored News £600 Sponsorship opportunities Contact sales for details
www.machinery.co.uk March 2017
JLR’S NEW HIGH-TECH QUALITY LAB AIMS TO SET THE STANDARD
Developments with3D printing in mind
CADCAM for AM
Bystronic’s rules for better bending
March 2
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achinery.co.uk
S E P A R A T E A E R O S P A C E S U P P L E M E N T
DRIVING DOWN DEFECTS
Totally automaticRobots, artifi cial intelligence & shopfl oor technology
001_MACH_MAR17.indd 1 23/02/2017 17:21
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THE INDUSTRY’S NO. 1 PRODUCTION EQUIPMENT JOURNAL FEBRUARY 2017 ISSUE 1
001_MYC_FEB01 FRONT COVER.qxp 26/01/2017 13:49 Page 1
www.machinery.co.uk @MachineryTweets May 2017 11
LEAD FEATURE MAGNESIUM AIRCRAFT COMPONENT SUPPLY CHAIN
Above: aircraft make use of multiple seat supports, meaning that weight reduction efforts on a single part are multipled manyfold
Inset: front leg and a side support – a spreader
These magnesium parts broke cover in April, at a Hamburg industry trade fair. It’s been a long journey. For 40 years, magnesium alloys have been
prohibited from use in commercial aeroplane seats by US design organisation the Society of Automotive Engineers on safety grounds (the restricting directive was worded “Magnesium alloys shall not be used”). Widely used in � reworks for its bluish white light, thin shavings of the metal are � ammable.
UK and US magnesium producer Magnesium Elektron (0161 911 1000) recently managed to overturn that blanket ban. In August 2015, SAE AS8049 Revision C allowed magnesium alloys in aircraft seats, provided that they meet certain US Federal Aviation Association (FAA) � ammability criteria. And Magnesium Elektron has established that its alloys ‘Elektron 21’ and ‘Elektron WE 43C’ comply with those, thanks partly to alloying elements that include yttrium (4%) and neodymium (2%), which tend to act in a self-extinguishing manner and also do not ignite below their melting point of at least 530°C – a temperature far above the melting point of other common aircraft cabin polymer wall panel materials.
Although it has been excluded from aircraft seating, the metal is by no means unknown in industry, thanks to
bene� ts that take in its light weight (the pure metal is 35% less dense than pure aluminium) and easy machineability. In particular, Elektron WE 43 was developed in the 1980s for making helicopter gearboxes; magnesium alloys are also used in automotive diecastings such as steering column components, transmission cases or instrument panel beams. The market for structural aerospace applications is limited by magnesium’s well-known propensity to corrode – it is used as a sacri� cial anode in cathodic protection of oil and gas pipelines in the North Sea, for example. This property requires the material be protected by highly engineered coatings, including an epoxy sealant.
All the same, there are perhaps 800,000 tonnes produced annually of this element, which is abundant in the earth’s crust, albeit a tiny fraction of the 60 million tonnes of aluminium produced annually, says Magnesium Elektron divisional technology director Martyn Alderman.
As part of a £279,000 National Aerospace Technology Exploitation Programme (NATEP) aerospace industry R&D project half supported by government, Magnesium Elektron teamed up with forging company Mettis Aerospace, machinist Kenard and seating manufacturer Geven to demonstrate a way to make two seat parts –
10 May 2017 www.machinery.co.uk @MachineryTweets
a front leg and a side support, collectively called a spreader – and develop a UK supply chain.
The manufacturing process begins when alloys are combined with a magnesium ingot in an initial 700°C melt at Magnesium Elektron’s Manchester foundry. They are then cast into an extrusion log 250 mm diameter by 4 m long, heat treated, then cut up into 1 m lengths and extruded into round, slightly tapered bar. They then travel to Mettis Aerospace in Redditch (01527 406400), where the larger part is bent and made into a 15 in-long, 8 in-wide banana-shaped preform, and then into a � nal forging that includes weight-saving die-formed pockets. Flash is also removed. Finally, both parts travel to a machinist – for the trials Dartford, Kent-based Kenard (01684 271400) – for � nishing. The completed larger part features a truss structure with stiffening ribs, produced in three operations (front face, back face and sides). Finish machining is an important stage in the process to reduce weight (in the case of the spreader, the process cut two-thirds of preform weight from the � nal 440 g part).
MACHINING MAGNESIUMAn important part of the research was a back-to-basics investigation of cutting magnesium – expertise of which is limited in the UK – carried out for the project by the University of Shef� eld’s Advanced Manufacturing Research Centre with Boeing (0114 222 1747). This produced calculated cutting force coef� cients for the alloy (ktc 317.7 MPa; krc 97.5 MPa; kac 111.7 MPa; kte 12.8 N/mm; kre 7.9 N/mm; kae -0.7 N/mm). It also simulated chip geometry, concluding that the maximum temperature encountered during a chip cutting operation would be 200°C, indicating little likelihood of setting the machine on � re. (Still, Magnesium Elektron guidance dictates that cutting paths in the alloy must avoid dwells that could generating � ne swarf or powder, as they are the most � ammable forms of the material).
To generate speed and feed recommendations, cutting stability trials began on Elektron 43 using a Sandvik Coromant CoroMill Plura solid carbide square shoulder end-mill (2P122-1600-NC H10F; www.sandvik.coromant.com/uk) on a Dorries Scharmann Ecospeed (0121 359 3637). Alderman explains: “The � rst reaction that the average machinist used to have, when [the process] hits vibration is to slow down the spindle to get a decent cut. But the AMRC has demonstrated that there are resonant frequencies associated with the tooling geometry, lubricants and the stiffness of the machine, and if you tune the machine using a tuning fork, you can identify them [the frequencies]. Then, once you start machining and get to the point where you start to hit resonance, by turning up the spindle speed, you get into a stable region.” AMRC researchers eventually identi� ed � ve stability lobes (at 5.3, 6.5, 8.5,14, and 29 thousand rpm) where it is possible to cut magnesium at greater
depths of cut than would be possible when processing aluminium alloys.
Dominic Henry, supplier quali� cation manager for aircraft interiors at Magnesium Elektron, who managed the project, explains the results in another way. He says: “We were able to show that the absolute stability limit of Elektron 43 T5 is nearly 2.5 times higher than [aluminium alloy] AW7075 T6, proving that magnesium can be cut successfully at very high spindle speeds that exceed the capability of many CNC milling machines, and that it has a wider process window than equivalent strength aluminium alloys.”
Machining trials were undertaken dry, for three reasons. First, Alderman calls the material less “sticky” under cut than aluminium, so naturally requires less Aluminium
alternative
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In a collaborative R&D project, Magnesium Elektron demonstrated the manufacture of aircraft seat supports that, on a fi nished part comparison, were 19% lighter than aluminium AW2024. The company is developing a supply chain and has big plans for growth, as Will Dalrymple learned
Magnesium machining practicalities Mean speci� c cutting force of magnesium (ks1.1) is 280 N/mm2, less than half that of aluminium, according to a Magnesium Elektron brochure. With a relatively reduced load on the cutter and tool body, higher cutting speeds and feed rates are possible (see above). Although the NATEP programme did not investigate optimising tooling, either uncoated carbide or polycrystalline diamond cutters are recommended.
Also, the company advises that extra swarf management precautions should be taken when cutting magnesium. Chips should be cleared regularly during machining and stored in closed drums, not only for safety, but also for economy, as its value as a recycled raw material depends on its purity. As magnesium alloy is most at risk of ignition when in powdered form, dust extractors and vacuum systems are recommended to remove mists of magnesium particulates so that they don’t settle on ledges, for example. Were the worst to happen, a magnesium � re is put out only by a powder-based (type D) � re extinguisher; both water and CO2 devices feed the � ames.
Stability lobe diagrams for Magnesium Elektron 43, Al6082 and Al7075
5000 10 000 15 000 20 000Spindle speed (rpm)
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MG Elektron 43Al6082Al7075
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