Whitehouse Machine Tools

Innovative High-volume Machining Of Aircraft Brake Clips

web@amiweb.co.uk — Mon, 23 Jun 2025 09:33:42 +0000

Founded in 1998 as a spin-off from the prestigious gunmaker Westley Richards, Westley Engineering has evolved far beyond its origins. While only five percent of its output now relates to gun components, the company has established itself as a trusted supplier of machined components and assemblies to multiple sectors including aerospace, automotive, rail, white goods and renewable energy.

Aerospace is its largest market, accounting for 45 percent of total production by value. A notable aerospace contract involves the manufacture of rotor clips used within aircraft disc brakes. Made from aerospace-grade steel and Inconel, the components are used in both civil and military aerospace programmes. Demand for these clips has risen significantly over the last few years.

The machining area of one of the Brother Speedio S700Xd1 30-taper machining centres on the shop floor at Westley Engineering’s Birmingham factory. It shows the fixture (right) with multiple inclined bars holding the brake clips, allowing hundreds of them to be presented for drilling and countersinking in one hit before the machine doors are opened again.

Three years ago, Westley Engineering improved the accuracy of the manufacturing process by switching from piercing holes in the clip on press tools to drilling them on a 40-taper vertical machining centre (VMC). Although it improved the precision, it also increased cycle times substantially and made the process more labour intensive.

So in late 2023, the company installed a Brother Speedio S700Xd1 4-axis, 30-taper machining centre, followed by a second in April 2025. Supplied by Whitehouse Machine Tools, the exclusive UK and Ireland distributor for the Japanese manufacturer, these high-speed machines have now replaced the VMC for production of the clips.

Close-up of the Schunk hydraulic vice on the rotary table, the workpiece sensor to the right of it, and the coolant-actuated workpiece gripper (top right).

John Harland, Managing Director of Westley Engineering said, “The arrival of the first Brother machine was a game-changer. Its exceptional speed, especially the 0.7-second tool changes, means each Speedio can machine clips 35 to 40 percent faster than with our previous setup.”

“The former VMC ran around the clock on weekdays and through the weekend. The new Speedios not only handle the entire production volume more efficiently, but also offer extra capacity for future growth.”

In partnership with Whitehouse Machine Tools, Westley Engineering implemented an automated, single-operation process on each Speedio. The new production route features custom-built fixtures with nine inclined bars, each capable of holding about 36 clips. This high-density arrangement enables over 300 parts to be machined per cycle, significantly more than the flat fixtures used previously.

The workpiece gripper in the tool carousel of the Brother S700Xd1.

Cycle times have been reduced to between two and three minutes per clip, depending on the variant. For example, the Inconel version requires additional milling on the outer arms, whereas the steel variants do not. Typical batch size ranges from 5,000 to 10,000 units.

Before deployment, the process was validated at Whitehouse Machine Tools’ Kenilworth technical centre. Its applications engineers wrote the machine programs, assisted with fixture setup and provided on-site training, all offered as part of the supplier’s lifetime service and support.

A coolant-actuated gripper, housed in one of the Speedio’s 28 turret positions, picks up each clip from the inclined bars. After verifying the workpiece position using sensors, the gripper transfers the part to a Schunk hydraulic vice mounted on a rotary axis.

The component is then machined – drilled, countersunk and in some cases milled – before being dropped into a container for post-processing. All clips undergo 100 percent inspection, including after heat treatment, followed by fettling as needed to correct any distortion.

John Harland (left), Managing Director of Westley Engineering with Paul Proctor, Machine Shop Manager.

Mr Harland noted, “Scrap has dropped to under one percent, down from up to four percent with the old process. And thanks to the energy efficiency of the Brother machines, we’ve cut power consumption by an estimated 60 percent.”

The post Innovative High-volume Machining Of Aircraft Brake Clips appeared first on Whitehouse Machine Tools.

Atkinson Equipment Slashes Lead-times by Automating Prismatic Machining

wmtcnc — Fri, 28 Feb 2025 12:49:50 +0000

A leading OEM specialising in the design and production of equipment for oil heating and diesel tank applications, as well as being a subcontract engineering firm, Atkinson Equipment has dramatically reduced lead-times following investment in a Brother Speedio U500Xd1 5-axis machining centre equipped with Tezmaksan CubeBox automation from Whitehouse Machine Tools.

Adam Walford, Engineering Group Sales Manager at Atkinson Equipment explained, “The automation solution from Whitehouse has increased our productivity dramatically. We have typically halved lead-times from 12 weeks down to six for complex subcontract parts and reduced them even further when making components for our own products, say from a month down to one week.

The Brother Speedio U500Xd1 5-axis machining centre equipped with Tezmaksan CubeBox automation on the shop floor at Atkinson Equipment.

“Since automating the milling side of the business, we have also seen a reduction in the bottleneck we previously had when parts arrive from our turning section for prismatic machining. Our ability to get product out of the door to our customers is through the roof. It is helping us to win new business in the subcontract area, as well as to grow our OEM division.”

Based in Westbury, Wiltshire, Atkinson Equipment is required to manufacture large volumes of parts for its own refuelling and liquid transfer products, which it has been doing for over 50 years. It also needs to produce a high mix of smaller volumes for the subcontracting division, which has been running for half that time, but which is growing rapidly. This dual role places significant demands on its manufacturing capabilities and was pivotal in the investment in the automated Brother-Tezmaksan cell.

Whitehouse assisted in the cell set-up in Westbury by supplying end-of-arm tooling with double grippers for handling raw material and finished components.

The relationship with Whitehouse Machine Tools began in 2019 with the purchase of a Brother 5-axis CNC machining centre, a Speedio S700X1 equipped with a Lehmann rotary-swivelling compound table. This initial investment allowed the company to machine complex parts on multiple faces in a single set-up, significantly improving efficiency. Having experienced the benefits, Atkinson Equipment went on to buy a Brother Speedio M200Xd1 trunnion-type 5-axis machining centre in 2023, initially to manufacture a complex aerospace part.

At first, the idea was to automate the existing S700X1 on site with the Tezmaksan CubeBox, but this would have necessitated an upgrade to the Lehmann equipment to provide pneumatic supply for automatic clamping of parts. However, a visit to the Whitehouse showroom in Kenilworth revealed the potential of automating a Brother U500Xd1 5-axis machining centre instead, as this was the configuration being demonstrated.

Adam Walford, Engineering Group Sales Manager, Atkinson Equipment.

Mr Walford explained, “Looking at the cost differential between just the Tezmaksan compared with the automation plus the U500Xd1, it made sense to go for the automated set-up complete with the new 5-axis machine. We needed extra capacity anyway, so it made absolute sense for us, especially as it was more affordable than we anticipated.”

The Brother U500Xd1’s large working volume for the compact footprint, 28-tool ATC capacity and integrated rotary joint for pneumatically actuating the fixtures proved ideal for the Westbury firm’s production needs. Whitehouse provided comprehensive support during the set-up process, assisting with tray template design for holding raw material and finished components, as well as the end-of-arm tooling with double grippers for handling them. The automated cell’s sensors create a safe working environment, without the need for traditional guarding.

The Atkinson Tankmaster is an OEM valve and sight gauge designed to monitor and control the oil level in a storage tank.

Mr Walford concluded, “It was quite daunting at first taking on a completely new piece of technology like this, but we were confident with the support that we would get from Whitehouse and their ability to guide us through the process to where we are now.

“The relationship with this machine supplier is key. We’re very happy with their service and support, it’s really brilliant, and it gives us confidence to keep buying from them.”

The post Atkinson Equipment Slashes Lead-times by Automating Prismatic Machining appeared first on Whitehouse Machine Tools.

Subcontractor Chooses 30-Taper Production Centre to Embark on 5-Axis Prismatic Machining

wmtcnc — Tue, 11 Feb 2025 16:48:07 +0000

Wisbech-based subcontractor Avant Manufacturing was using four 40-taper, 3-axis VMCs (vertical machining centres) when, towards the end of 2024, a sharp upturn in existing and new business meant that an extra machine was needed quickly.

Dominic Roach, who founded the company in April 2021, wanted to install a 5-axis production centre to reap the benefits of fewer reclampings of parts. The advantages are principally higher speed of production, and less risk of errors and damage to workpieces due to excessive manual handling. He also wanted to be able to produce more complex components, preferably in one hit. However, the space remaining on the shop floor was limited and 5-axis machines tend to be large.

The answer to the conundrum was to install a Brother Speedio U500Xd1 5-axis, swivelling-trunnion VMC with a 30-taper spindle from Whitehouse Machine Tools, sole UK agent for the Japanese manufacturer. Having a 1,560 x 2,026 mm footprint, the machine fitted neatly into the available space when it was delivered in December 2024.

First class honours engineering graduate Dominic Roach (left), owner of Avant Manufacturing, and Tom Newman, who was next to join the company in January 2022. There are now five employees.

Subcontractors are increasingly moving towards the 30-taper interface, especially with the BIG-Plus face and taper contact option, as it combines 40-taper rigidity with the exceptionally high speed motions of which the smaller form factor machines are capable.

Mr Roach commented, “The Brother practically sold itself. We couldn’t find a 40-taper machine that would fit, while other 30-taper equipment suppliers had a limited number of production platforms and automation possibilities in their range, which would have limited our future options.

“Additionally, I was drawn to the Brother because it is a true 5-axis machine, not a 3-axis model with a bolt-on compound table. An added bonus is that Whitehouse offers unlimited ongoing technical support and is very quick to respond when we have a query. Someone always gets back to us within half an hour.”

The M200X3 is one of 10 VMCs on the shop floor at R&A, working alongside eight CNC turning centres.

As he was swapping to a smaller diameter tool holder that he had never used before, Mr Roach was keen to satisfy himself that the Brother machine was powerful enough to remove metal quickly. Admittedly most of the material going through the shop is aluminium, with the remainder mainly plastic, but often billets are reduced to 10% of their original size, such as a medical robot part that is regularly produced. In one recent instance, a 72 kg block of 6082 aluminium was milled down to a weight of 4 kg, a reduction of more than 94%.

With a similar aluminium billet and some Ceratizit roughing end mills, he drove 100 miles west to Whitehouse Machine Tools’ showroom and technical centre in Kenilworth to put a U500Xd1 through its paces. He said, “I was impressed not only by the metal removal rate, but also by the size of parts that can be produced in such a small footprint.

“I would have no hesitation producing components from tougher materials either, as it’s an easy matter to change the machining strategy to limit the width and depth of cut and increase the spindle speed and feed rate.”

All programming is off-line at a seat of Autodesk Fusion.

Since there was an urgent need in Wisbech for the additional spindle, he decided to rent a U500Xd1 straight away ahead of taking delivery in April 2025 of a more capable model, a U500Xd2. Whitehouse duly supplied the rental machine and provided two days of on-site training.

The upgraded U500Xd2 has longer travels in X and Y, giving a working volume of 500 x 450 x 380 mm. Rotary axis motions are the same, as are the 16,000 rpm BIG-Plus spindle and the 28-position tool magazine, but the control is full 5-axis rather than 4+1. A high-accuracy mode option with 1000-block look-ahead has been selected, as well as 35 bar high pressure coolant, and Blum probes for checking cutter length and workpiece position. Chip-to-chip time is fast at 1.4 seconds owing to simultaneous tool change and rapid traverse in the linear and rotary axes.

To indicate how much faster the U500Xd1 is, and the U500Xd2 will be, compared to one of his 40-taper VMCs, Mr Roach cited a scientific part produced from solid aluminium that formerly required four separate set-ups on 3-axis machines. The number of operations has been halved and the same component is now produced in 36% of the time. That is because although Op 1 is the same, Ops 2, 3 and 4 are now completed on the 5-axis Brother in a single clamping using the rotary axes to position the part for 5-sided machining.

The rotary axes of the VMC are part of the machine design, not added on.

A job completed in January 2025, involving drilling 60 holes at eight different angles into a medical plastic block, could not have feasibly been done on the 3-axis machines. So the availability of the Brother is allowing Avant Manufacturing to gain new business that it previously had to turn down.

A difference that was noticeable immediately the U500Xd1 was installed was the better milled surface finish on components, which far surpasses any customer requirement received to date. Dimensional tolerances held are tight, down to below 10 microns, despite there being no temperature control in the factory.

Looking to the future, for obvious reasons Mr Roach is looking to move to larger premises and has first refusal on an adjacent unit on his current industrial estate in Wisbech. He is committed to continuing the journey towards 30-taper, 5-axis machining to provide increased capacity for both large and small batch production, especially for the medical, pharmaceutical and scientific industries that he mainly serves, as well as for the control, automation and defence sectors.

The post Subcontractor Chooses 30-Taper Production Centre to Embark on 5-Axis Prismatic Machining appeared first on Whitehouse Machine Tools.

Fast, Versatile Machining Centre Helps Win New Business

wmtcnc — Tue, 11 Feb 2025 16:41:35 +0000

Larger components produced a third faster in half the space

Michael Phillips, joint owner with partner Wayne Robins of contract machining firm Atomic Precision, describes their recently-purchased, Japanese-built Brother Speedio U500Xd1 as “a Swiss army knife of 5-axis machining centres”. His comment is due to the 30-taper machine’s high quality, versatile functionality, compactness, and ability to complete an extensive range of jobs quickly and efficiently. Brother machines are sold and serviced in the UK and Ireland by sole agent Whitehouse Machine Tools, Kenilworth.

Atomic Precision partners Michael Phillips (left) and Wayne Robins with their Brother Speedio U500Xd1 30-taper, 5-axis machining centre.

Founded in East Hendred, Oxfordshire, in 2020 by the two time-served mechanical engineering apprentices, who both previously worked in the machine shop at nearby Rutherford Appleton Laboratory’s space development facility, Atomic Precision specialises unsurprisingly in manufacturing components and assemblies for the space and scientific research sectors.

A succession of 40-taper vertical machining centres (VMCs) from another supplier arrived on the shop floor over the next four years, three 3-axis models and two 5-axis machines. During that time, the subcontractor enjoyed an impressive growth rate of 50% year on year.

It was clear to the two partners, who work alone, that the ongoing rate of growth was unsustainable without progression on the shop floor to more efficient machine tools, and perhaps also automation to gain substantial periods of unattended production. They operate a single day shift and working longer hours is not part of their game plan.

The partners say that having confidence in the machine tools they buy is crucial, as an ill-judged purchase can have serious consequences for a small enterprise.

As a first step to raising productivity, the high-speed Brother U500Xd1 was installed and commissioned by Whitehouse Machine Tools in September 2024. The partners became aware of the machine at the Southern Manufacturing exhibition in Farnborough in early 2023. After early hesitation regarding the smaller spindle interface, which later proved to be a non-issue, and benchmarking a couple of other 30-taper machines on the market, the order was placed.

Mr Phillips commented, “The area taken up on our shop floor by the U500Xd1 is half of the space that one of our 40-taper 5-axis machines occupies, yet the 30-taper VMC actually produces larger parts.

Michael Phillips operating the U500Xd1.

“Not only that, but the Speedio finishes an identical component in two-thirds of the time, as the non-cutting elements of cycles are incredibly short, so tools are in-cut for typically 90% of the time during a cycle.

“The linear axes accelerate at 2.2 g up to 56 m/min and chip-to-chip time is 1.3 seconds. Rotary positioning by the trunnion and table are similarly fast and parts come off complete, resulting in really quick floor-to-floor times.”

The machine installed in East Hendred is a well-specified version of the Speedio model, with a 16,000 rpm / 15 kW spindle, 28-position tool turret, high pressure coolant, and Blum tool and part probing. Axis strokes are 500 x 400 x 300 mm, but multi-face machining of components up to 500 mm in diameter by 270 mm high and weighing up to 100 kg is possible owing to the layout of the machining area. Remarkably, this happens in a 1,500 x 2,490 mm footprint.

Machining area of the U500Xd1.

As well as producing parts up to the maximum working envelope, the Speedio also machines very small components requiring complex features cut with a 0.2 mm diameter end mill, hence the decision to opt for the highest speed spindle Brother offers. Extensive use is made of towers for fixturing multiple smaller parts to extend walk-away time from the machine if individual cycle times are short. Batch size is normally up to 10-off, although often single prototypes are machined.

The low power consumption of 30-taper machines per se, and especially of Brother Speedios, leads to a significant lowering of electricity bills.

However, in November 2024, Atomic Precision received an unusually large order from a new customer for 400-off aluminium brackets requiring a 3+2 machining strategy, using the rotary axes to position the part. The subcontractor could not have accepted the contract if it had been unable to use the elevated speed of the Brother machine. A 5-axis, 40-taper VMC would have been too slow to meet the three-week lead-time, so the subcontractor would have had to turn down the work. If more jobs involving quantities of several hundred start coming in, automating the Brother and indeed other VMCs on-site will go ahead imminently.

A large variety of materials is processed in the factory, including aluminium, stainless steel, brass, copper, tungsten and tantalum. Mr Phillips advises that it is possible to hold ± 10 microns dimensional tolerance “comfortably” on the Speedio, even without climate control in the factory.

A selection of space and scientific components produced by Atomic Precision on its 5-axis machining centres. Many are being transferred to the Brother Speedio to reap the benefits of more efficient production.

He concluded, “The service we have received from Whitehouse throughout the sales and installation process has been brilliant – and if we need advice, they come straight back to us with an answer.”

The post Fast, Versatile Machining Centre Helps Win New Business appeared first on Whitehouse Machine Tools.

Brother machining centre halves cycle times

wmtcnc — Tue, 05 Nov 2024 13:12:05 +0000

Aylesbury-based R&A Engineering won a contract in early 2023 to produce several hundred aluminium parts per month across six variants for assembly into sensors that optimise the orientation of wind turbines to maximise the power they generate. The job was tying up a pair of BT 40-taper VMCs (vertical machining centres) on the shop floor and impacting the subcontractor’s ability to take on other work. So the decision was taken to transfer production to a 30-taper, high-speed VMC, prompting an order to be placed for a Brother M200X3 with a 16,000 rpm spindle.

Delivered in August 2023 by the Japanese manufacturer’s sole agent in the UK and Ireland, Whitehouse Machine Tools, the Speedio M200X3 5-axis VMC has on average halved the time it takes to complete post-anodising milling, drilling and tapping operations on the six components. The machine is therefore able to perform the same work as the two VMCs used previously, which are now free to carry out other work.

Ed Piotrowski, operations manager at R&A said, “We approached a couple of 30-taper VMC suppliers but Whitehouse was the obvious choice, even though we have never bought a machine from them before.

“It is a family-run firm like ours and has a similar ethos as regards providing a high quality service, which was obvious when we visited their showroom in Kenilworth a couple of times for demonstrations.

“The Brother performs very well. Cycle times are now between one-and-a-half and four minutes, half of what they were before, and the ± 0.05 mm tolerance is held all day long without any problem. It is a really accurate machine.”

Ed Piotrowski, operations manager at R&A, holding an aluminium EV engine terminal block machined on the Brother 5-axis Speedio M200X3 machining centre.

Established in 1985 by Ed’s parents, Richard and Alison, and currently employing 18 staff, R&A has grown by 50% since 2021. It has invested £800,000 in machine tools during the past couple of years and is looking to automate production wherever possible in both the turning and milling sections. The rationale is twofold: to be able to take on extra work without compromising existing, long-running contracts; and to be more cost-competitive on the world stage to accelerate the flow of work that is already being reshored from Asia and elsewhere in increasing quantities.

Ed has some interesting insights into why a subcontractor should invest in a 30-taper VMC, bearing in mind that an adage in contract manufacturing is that one never knows what work will come through the door next. The wider applicability of a 40-taper machine due to its size and power would therefore seem to make more sense.

The first advantage of a nimble milling machine with the smaller diameter tool interface is high speed production, which translates into greater profitability. Not only does the elevated spindle speed combined with up to 30 m/min cutting feed rate provide generous metal removal rates, but idle times are lower due to 50 m/min rapids in X, Y and Z and tool change in under one second.

The M200X3 is one of 10 VMCs on the shop floor at R&A, working alongside eight CNC turning centres.

A less well known benefit is the vastly lower power consumption of 30-taper machines. Ed advised that the M200X3 draws less than 10 kVA, versus typically 50 kVA for a 40-taper VMC or perhaps even more if it is an old machine. Energy bills are therefore lower and, as is the case at the Aylesbury facility, if a factory is close to its power supply limit the lower kVA rating is a godsend.

Reviewing the characteristics of the respective BT spindle machines, Ed observes that while power and rigidity are higher in a 40-taper VMC, modern, smaller-taper counterparts such as the Brother have a reasonably well specified spindle motor with good torque, even in the medium- to high-speed range. The drive motors are also consistent with robust machining and face-and-taper-contact tool retention assists further, as in R&A’s case.

He added, “Although machining of light alloys is really the province of this type of machine, using modern CAM software to create intelligent cycles involving light depths of cut and high-speed contouring means that tough and difficult-to-machine metals can also be tackled.”

The machining area of the trunnion-type M200X3 5-axis VMC, which is capable of in-cycle turning operations. Some of the cutters in the 22-station tool magazine may be seen at the top.

The M200X3 has a further advantage for OEMs and subcontractors alike. It is equipped with a torque motor to drive the rotary table, allowing a component not only to be indexed, but also to be rotated at up to 2,000 rpm so it can be machined with a static turning tool in the spindle. Completing this second operation in-cycle without the need to re-fixture the part in a lathe simultaneously raises accuracy and productivity.

The mill-turn capacity in an impressively small footprint holds a lot of potential on the shop floor at R&A. Take, for example, the wind turbine sensor job for which the machine was purchased. Currently all six parts undergo turn-milling on a lathe before being sent out for anodising. The Brother is only required to remove the insulative anodic layer in certain areas to provide electrical conductivity. With the latter machine’s turning capability, all of the parts could be completely machined. Richard and Ed are actively considering this possibility, which would require automated component handling to be retrofitted.

A selection of parts machined by R&A. The EV engine terminal block is centre back, the Ertacetal water purification part being lined up for mill-turning on the M200X3 is pictured left, and the remainder of the components are parts for the wind turbine sensor assembly.

In addition to seizing opportunities in the renewable energy sector, R&A is also taking advantage of growth in vehicle electrification. Two aluminium parts have already been produced on the Brother VMC for the latter sector. One is an EV (electric vehicle) engine terminal block, which is milled, drilled and tapped in a 20-minute cycle. Another engine part has been transferred to the M200X3 from a 40-taper machine, with the result that it is now machined in eight minutes rather than 12, again leading to more competitiveness, shorter lead times that impress customers and more overall capacity on the shop floor.

Ed is already planning the next job for the Brother. Water purification work accounts for about one-third of the subcontractor’s turnover and one of the parts machined from Ertacetal, an electrically conductive plastic, is currently turned and milled in four set-ups on three other machine tools. On the Brother it will come off complete after two set-ups.

The post Brother machining centre halves cycle times appeared first on Whitehouse Machine Tools.

S700Xd2

wmtcnc — Thu, 31 Oct 2024 13:35:12 +0000

SPEEDIO’s bestselling S model further expands the range of application Enlarged machining area and using a 28-tool magazine expand target workpieces and promote process integration. Advanced CNC-D00 controller improves environmental performance and productivity. Extensive range of specifications available to meet a wide variety of machining applications.

Travels X:700mm Y:450mm Z:300mm/380mm
28-tool magazine
High acceleration Z-axis Max. 2.2G
Rapid traverse rate (m/min) X/Y/Z 50/50/56
Spindle start/stop time 0.15S or less
12,000 rpm spindle speed
Higher machine rigidity and minimal vibration
7 MPa Coolant Through Spindle (CTS) (optional)
Available in a variety of bed lengths

The post S700Xd2 appeared first on Whitehouse Machine Tools.

U500Xd2

wmtcnc — Wed, 23 Oct 2024 13:34:34 +0000

Universal Compact Machining Center Performs universal indexing, encouraging process integration Standard equipped with a tilting rotary table with a maximum jig area of ø500 mm. Increased travels of Y/Z axes enable a wider range of multi-face machining. SPEEDIO’s high-speed performance and process integration through multi-face machining enhance productivity at customers’ premises more than ever before. One-clamp operation achieves highly efficient and highly accurate machining in various industries.

Travels X:700mm Y:450mm Z:380mm
Expanded jig area
28-tool magazine
Equipped with tilting rotary table that uses roller gear cam
Z-axis acceleration Max. 2.2G
Spindle start/stop time 0.2S or less
Automatic door opening/closing time 20% less
High clamp torque
Highly efficient 12,000 min-1 spindle motor
7 MPa Coolant Through Spindle (CTS) (optional)

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Interconnected technologies in CNC machining

wmtcnc — Thu, 31 Oct 2024 15:08:05 +0000

Manufacturers embrace modularity with CubeBOX automation system

Bill Gates believes that Generative artificial intelligence (GenAI) has potential “to change the world in ways that we can’t even imagine,” highlighting its potential to innovate and enhance productivity across various sectors. For manufacturers striving to remain competitive and meet the evolving demands of the metalworking industry, embracing such technologies will be crucial. Here, Hakan Aydogdu, general manager of CNC automation system manufacturer, Tezmaksan Robot Technologies, explains how embracing modular and adaptable technologies, complemented by GenAI, can help manufacturers improve efficiency, reduce costs and stay competitive.

The landscape of CNC machining stands on the brink of significant change, largely driven by GenAI. In his blog, The age of AI has begun, Gates notes this technology could address major global issues such as climate change and disease, with implications for manufacturing that extend beyond mere operational improvements.

Recent research by McKinsey & Company indicates a rapid adoption of GenAI, with 65 per cent of organisations integrating it into their operations—almost double the rate from the previous year. This trend is particularly notable in product development and IT, sectors integral to manufacturing. The same study reports that GenAI is proving valuable for optimising supply chain operations and inventory management, leading to revenue increases of over five per cent for many manufacturers through improved demand forecasting, automated inventory tracking and streamlined logistics.

Challenges in integration

Nevertheless, the integration of GenAI into CNC machining presents challenges. One major issue is synchronising advanced AI systems with existing machinery, which often necessitates costly modifications to infrastructure. IBM Research highlights that overcoming these compatibility issues can be both time-consuming and expensive.

Smaller manufacturers face additional hurdles due to the high costs associated with advanced automation and AI technologies. Ongoing investments to keep pace with rapid technological advancements can strain financial resources. The July 2023 AI Pulse Survey by Forrester notes that many organisations are struggling with the financial pressures of continuous technology upgrades, compounded by the need for frequent maintenance and system customisation.

Modular and adaptable solutions

To address these challenges, modular and adaptable technologies are emerging as viable solutions. These systems offer greater flexibility and ease of integration with existing setups. They can be tailored to specific needs and scaled as required, minimising disruption during technology implementation.

In a smart factory, modular and adaptable technologies facilitate flexible production lines. Robots and machinery are designed to be modular, so only specific components—such as tooling or programming modules—need adjustment when introducing a new product line. This flexibility allows for quick transitions between different production runs with minimal downtime or additional costs.

Adaptable Internet of Things (IoT) technologies play a crucial role in modern manufacturing. These systems use sensors, data analytics and connectivity to provide real-time data from various parts of the production line. IoT devices can be reprogrammed or recalibrated to track new metrics or communicate with different devices as production needs evolve. For instance, if a factory begins manufacturing a new product, sensors can be updated to monitor different quality control criteria without overhauling the entire system.

Simplifying implementation

However, integrating modular and adaptable technologies with existing systems remains complex. Many organisations still use legacy infrastructures not designed for modern, flexible solutions, making the transition both time-consuming and costly. Customising and scaling these technologies often requires specialised knowledge, creating potential bottlenecks during implementation. Ensuring seamless communication between new modules and older systems, while maintaining efficiency and minimising disruption, is a significant challenge.

Here, generative AI plays a vital role. IBM Research points out that GenAI’s ability to automate code generation and simplify complex processes can help streamline the integration of new technologies. This capability reduces the need for extensive manual programming and system adjustments, thus enhancing overall operational efficiency.

Consider the CubeBOX, a compact, adaptable automation system designed to streamline the operation of CNC machines. This system enhances productivity by automating loading and unloading processes, allowing the machines to run continuously around the clock without human intervention.

The CubeBOX features a cost-effective, plug-and-play design that integrates easily with various CNC machines and robot brands. The system’s ability to handle pallet changes while the machine operates and its user-friendly software—converting CAD designs into machine instructions—demonstrate its effectiveness in increasing productivity, particularly during night shifts.

Increasingly competitive

The system’s modular design allows for easy adaptation and movement between machines, making it a versatile solution for different production needs. It is compatible with a range of CNC machines, including lathes, machining centres and grinding machines and is priced 20 per cent lower than comparable solutions.

Complementing this system is ROBOCAM, an intelligent automation software that simplifies programming. ROBOCAM enables operators to upload product drawings, which are then converted into commands for the robot. This user-friendly software reduces the need for extensive programming knowledge and accelerates the implementation process, addressing a common challenge in automation adoption.

Imagine a mid-sized manufacturing company that produces high-precision components for the aerospace industry. Traditionally reliant on manual CNC machine tending, the company faces high labour costs and downtime, particularly during night shifts. By implementing this robotic automation system, the company could run its CNC machines continuously, increasing night shift efficiency by 50 per cent and reducing lead times. The system’s compatibility with various machines allows for seamless integration with minimal downtime. ROBOCAM further enhances efficiency by simplifying programming, allowing for quick adjustments to new product designs and production runs.

As the industry adapts to these transformative technologies, the future of CNC machining is set to be shaped by innovations such as this robotic automation system and ROBOCAM. By embracing these advancements, manufacturers can enhance efficiency, reduce costs and position themselves for sustained success in an increasingly competitive landscape.

To learn more about Tezmaksan’s CubeBOX automation systems, visit the website.

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Robust, Powerful Lathe Enables Broaching Of Stainless Steel

wmtcnc — Fri, 04 Oct 2024 11:40:15 +0000

Components produced eight times faster in one hit

Architectural ironmongery manufacturer Instinct Hardware (www.instincthardware.co.uk) has spent more than half a million pounds in the last two years on a manufacturing execution system, a powder coating plant, a water jet cutting machine and an Italian-built Biglia bar-fed, twin-spindle lathe with a turret having a ± 45 mm Y-axis and 15 driven tools.

It is the sixth CNC lathe and by far the most capable to be installed in the 68,000 sq ft factory in Stirchley, Birmingham, where premium quality (commercial Category A fit-out) door knobs and handles, door stops and accessories are manufactured, predominantly from 316 stainless steel.

The latest turning centre was sourced in May 2024 from sole UK agent Whitehouse Machine Tools (www.wmtcnc.com), Kenilworth, which supplied the machine as a turnkey package with a Hydrafeed short bar magazine for feeding 1.5-metre long stock up to 80 mm in diameter, and a gantry-type system for unloading components onto a conveyor.

The Biglia B 620 YS on the shop floor at Instinct Hardware’s Stirchley factory.

This handling method was chosen to prevent damage to the surface of components and hence preserve their aesthetic appearance after they have subsequently been polished by hand to a mirror or satin finish. Supplied also by Whitehouse were programs and tooling for the production of two key components and their prove-out in Kenilworth, plus the provision of comprehensive training, which is unlimited and free of charge for the lifetime of the machine.

Instinct Hardware products, which are either standard catalogue items or manufactured to customers’ bespoke designs, have been or are being used in many prestigious projects. They include the ongoing refurbishment of Citibank UK’s London headquarters, Google’s new headquarters in King’s Cross, various London Underground stations, the recent renovation of Wembley Stadium and Liverpool FC’s modern training centre.

Until now, stainless steel has accounted for 80% of production, with the remainder mainly brass and bronze. However, an increasing amount of aluminium is being processed due to its easy recyclability, a material that will benefit even more from the careful, conveyorised handling. Timber handles with stainless steel cores are also on the rise. Marketed under the Mirage brand name, one quarter of production ends up in overseas markets, exported either directly or indirectly.

Instinct Hardware director Nil Chohan in front of the Biglia lathe.

Nil Chohan, one of the manufacturer’s second-generation directors explained, “Since we moved to our current premises, we have been steadily increasing our machining capacity with a view to reducing our reliance on subcontractors, which is now virtually zero.

“All of our lever handles require a square hole to be broached. This has always been done here in a separate operation on a hydraulic press, as before the Biglia B 620 YS was installed, we did not have a lathe on the shop floor rigid enough to perform the operation.

“We bought the Italian turning centre specifically because it is able to broach our stainless steel handles, which Whitehouse demonstrated to us before we committed to the machine. So we can now perform all operations in one hit, rather than in five or six operations using our previous production route.

“It significantly reduces scrap rate by avoiding repeated manual setups and greatly speeds manufacturing time, enabling us to fulfil more easily our promise to customers of a 10- to 14-day order turnaround.”

Working area of the twin-spindle, single-turret Biglia B 620 YS, in which components are turned, milled, drilled, tapped and broached from bar, exiting the lathe after reverse-end operations are completed in the sub spindle, without ever needing to be set up again on another machine.

A case in point is the machining of a component that is assembled into a stainless steel, oval-profile, mitred lever handle. It previously required six machining operations: turning on a 2- or 3-axis lathe, milling and drilling on one of four vertical machining centres (VMCs), broaching on a hydraulic press, further prismatic machining on a different VMC, slotting on yet another VMC (which could have been carried out on the previous machine, but the overall cycle would have been too long to achieve the required takt time), and mitring on a bandsaw prior to welding.

Part of a stainless steel, oval-profile, mitred lever handle is shown in the background. It is pictured with the constituent component (front right) that is now machined in one hit on the Biglia lathe rather than in six separate operations. Front left is a stainless steel coin slot bathroom release rose, whose slot is milled using the Biglia’s Y-axis.

All of this consumed a total of 15 minutes machining time plus 10 minutes or more handling and setup for each of the five additional operations, amounting to well in excess of one hour overall. On the Biglia, the part comes off complete in 8.5 minutes, representing about an eight-fold time saving, with the added benefit of elimination of in work-in progress and the attendant potential for damage to components.

Mr Chohan visited the Biglia factory in Italy with a Whitehouse sales engineer to see the lathes being built and get a sense of the quality of manufacture. Needing a strong, powerful machine capable of broaching stainless steel, he was impressed by the specification of the B 620 YS, in particular the 30 kW direct-drive, liquid-cooled main spindle motor offering 700 Nm of torque.

He was told that the latest design of this 6.5-tonne machine incorporates a massive, cast iron machine bed that has been reinforced by 20% compared with the model it superseded. It is notable that to promote rigidity and accurate machining, the lathe has box ways in the X and Y axes, with a linear guide rail in the Z-axis for speed of traverse.

The Biglia lathe is fitted with the latest Fanuc iHMI control. Programs are prepared using seats of Solidworks CAD and Autodesk Fusion 360 CAM software, with simple elements of cycles entered manually at the machine to ease the load on the programming department.

In a recent development, he mentioned that under the trading name of Instinct Hardware’s parent company, Creative Manufacturing (www.creativemanufacturing.co.uk), a subcontract prototyping and manufacturing venture has been embarked upon. A full service is offered encompassing design, machining, powder coating, shot blasting, assembly and packaging. It is early days and projects completed so far have involved waterjet cutting and painting, but all of the current 10 CNC lathes and machining centres on the shop floor are also available for deployment.

Mr Chohan concluded, “Reputation is hard to establish but even more difficult to maintain. Through hard work and endeavour, we have become a leading European manufacturer of bespoke architectural ironmongery.

“Today, our team is committed to continued investment and developing our range and brand further, with increased focus on sustainability of materials and logistics.

“We are constantly looking at new machinery like the Biglia to develop and enhance our offering, whilst maintaining our passion to continue driving the company and our industry forward.”

A typical Instinct Hardware lever handle on a hotel room door.

The post Robust, Powerful Lathe Enables Broaching Of Stainless Steel appeared first on Whitehouse Machine Tools.

Fastener Manufacturer Places Repeat Order For Italian-Built Lathes

wmtcnc — Tue, 06 Aug 2024 13:55:30 +0000

LoneStar Fasteners Hydrobolt Ltd (www.lsfe.com – LSFH), a leading global manufacturer and distributor of high-specification fasteners, bolts and other precision machined components, has placed a repeat order for turning centres to further expand CNC turn-milling capacity at its Wednesbury facility. The company is investing £1.5 million in a total of six twin-spindle Y-axis lathes built by Biglia in Italy, supplied through sole UK and Ireland agent Whitehouse Machine Tools, Kenilworth (www.wmtcnc.com).

The reason for LSFH buying the more modern production plant is to manufacture nearly every component more efficiently and to tighter tolerance in one hit, rather than in two, three or even four operations, as previously.

The decision to invest in the Biglia brand was based on the rigidity of the lathes and the high power of their spindles and driven tools, which enables the manufacture of components in tough metals such as stainless steel, titanium and high nickel alloys. These materials are commonly used in the oil and gas, petrochemical and power generation sectors, all of which are supplied by LSFH. To preserve surface finish on components and prevent damage after machining, a parts catcher and conveyor are fitted to every lathe.

The latest two Biglia lathes to be delivered to LSFH in May 2024.

Robbie Beckett, Operations Director at LoneStar’s Wednesbury facility commented, “The first two machines, installed in early 2023, were B620YS single-turret turning centres having 80 mm bar capacity, which have enabled us to reduce production costs, improve surface finish on components and increase productivity. They performed exceptionally well over their first year of operation, so we decided to order four more turn-mill centres from the same supplier.”

The next pair of lathes to arrive, in May 2024, were a Biglia B750YS having a single turret and 100 mm bar capacity, and a B465T2Y2, the first with twin turrets. They will be followed in August this year by an additional B750YS and another twin-turret lathe, a BMX45T2Y2 with superimposed machining capability, allowing three tools to be in cut simultaneously.

Mr Beckett continued, “Before we opted for these lathes, I visited the factory in Italy to see them being manufactured and meet the people. I was impressed with the quality of build and also the fact that the company concentrates exclusively on making lathes.

“Good after-sales service was also crucial for us. We were satisfied that it would be forthcoming from the OEM and from the UK agent, which offers unlimited training and applications support.

“This significant investment reinforces our commitment to technological advancement and maintaining our position as a global leader in our field. The Biglia lathes are allowing us to produce complex parts with exceptional precision, enabling us to raise operational efficiency significantly and deliver consistently high quality products to customers, on time and cost effectively.”

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