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At the heart of... UK Manufacturing How to save money in Auto Emerging Technologies update
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issue 2 2012
CONTENTS
GTMA President Foreword News New Members Annual Meeting News AT THE HEART OF... MANUFACTURING UK Precision Engineering - Overview What we do A-Z of companies Case Studies Press Tools Overview A-Z of companies What we do Case Studies Emerging Technologies AUTOMOTIVE FOCUS MMM 2012 Showing off solutions Exhibitors Case Studies Press Releases AEROSPACE TCT Live and more Events and Next Issue 3 4-5 6-7 8 9 10-23 12-13 13 14 15-17 19-20 20 21 21-23 24-25 26-35 36-51 38-39 39 40-51 52 53-55 56-57 58
Cover photo: Courtesy Delcam UK. Photos page 11 courtesy (l to r) top: Erodex, Bayer Healthcaare, Nissan, Sunseeker and, bottom: Bombardier, Rolls Royce, Ninian Peckitt and Airbus. Page 53 (l to r): AgustaWestland, BAE Systems, Airbus and Bombardier.
Contact GTMA In order to receive a copy of this GTMA News please phone, fax or email your request to GTMA. We do not accept responsibility for omissions or errors. Please note the views expressed in articles by contributors and advertisements included in this edition do not necessarily represent those of the GTMA.
Published by: Gauge & Toolmakers Association The National Metalforming Centre, 47 Birmingham Road, West Bromwich, B70 6PY Tel: 0121 601 6350 Fax: 0121 601 6378 Email: admin@gtma.co.uk Web: www.gtma.co.uk
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delegates and as we went to Press the first Tooling Alliance Group was being set up. It involves 10 companies and GTMA will now begin matching the skills and expertise to possible projects in specific sectors. It will then go in and discuss projects with the targets. The initiative is strongly focused on helping OEMs and Tier 1 buyers and part of the process is to audit Alliance companies in areas such as traceability. Benefits for the customer, says GTMA CEO Julia Moore, include the ability for the Tooling Alliance groups to become involved in design development bringing their knowledge of the tool into the concept stage of design where 80% of manufacturing cost is determined.
Tooling Alliance groups can reduce product product cycle times by eliminating waste, improved product development co-ordination, inventory reduction and joint Failure Mode Effects Analysis (FEMA), she said. Profit improvements for the first year for one customer and moulder, for one product, come from cutting lead time by a week, commissioning time by one week, reduced scrap, and productivity gains of 10%. These are viewed as minimum savings. The Alliance members benefits include: Reduced cost of tendering for contracts and dealing with suppliers Shorter time to market, partly because of openness of design information Technical Supplier team to
Member companies
who want to become involved in the tooling alliance initiative are asked to contact GTMA for more information, by email to julia@gtma.co.uk or tel: 0121 601 6350.
present to the customer Shared risk with a team approach on market correct pricing and affordability Shared marketing costs on the big projects Project management to be done by GTMA appointed managers. Over-riding these however is that once the Alliance has successfully worked together the aim is that they continue to do so.
Tal himself have received the implants, all of them manufactured by CRDM. www.crdm.co.uk
Survey moves on
Over 2,600 companies have now been contacted as part of the GTMA's UK Toolmaking Survey 2012, the first such detailed look at the sector for over a decade. Final calls are being made as we went to Press and the numbers declining participation or due for call back is just 8%. Work on analysing the responses will begin shortly with the final report due out early in the new year.
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The result is a cutting-edge turnkey manufacturing system that operates with very little human intervention and a minimum of scrap material. Andrew Snow, Regional Sales Director, EOS of North America, said: "While the demonstration at IMTS was of a medical component, this type of process chain is applicable to practically any industry. A look around the stand allowed visitors to see a range of parts for the aerospace, automotive, tooling with conformal cooling, consumer and other sectors. www.gfac.com.uk www.eos.info
A titanium tibial tray for a surgical knee implant it was produced by additive manufacture, 5-axis milling and wire EDM.
piece. It then undergoes conventional machining, first on a Mikron HPM 450U 5-axis mill and then on a CUT 20P wire EDM machine, both from GF AgieCharmilles, which unveiled the venture on its stand. This blend of technologies goes far beyond what most other product developers are presently doing, said Gisbert Ledvon, Business Development Director at GF AgieCharmilles in the US.
Information: admin@gtma.co.uk
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Spectrum Metrology
Sector solutions: Spectrum Metrology is a specialist company providing measurement solutions across sectors including aerospace, automotive, calibration, medical and precision engineering. The product range is used for a range of applications throughout the world and covers: Portable 3D coordinate measurement systems Workshop surface roughness, Taylor Hobson (workshop surface finish/roundness, Alignment, Angle and Level), FARO (Gauges) and Brunson (laser tracker accessories). But with many years metrology experience Spectrum Metrology is not just a distributor: It takes the time to understand customer applications study their drawings measure their components and then offer them the best solutions to their measurement problems.
roundness and form Electro-Optical Metrology Laser Tracker Accessories Dimensional measurement products (contact and non contact) Gauging and Transducers.
www. spectrum-metrology.co.uk
Autodesk Partner: Man and Machine is a Platinum Awarded Autodesk Partner, specialising in the supply of CAD solutions to manufacturers, engineers and product designers. With over 60 years of combined technical expertise, it can empower you to design and visualise better. Autodesk suites and its AutoCAD and other software are powerful tools for design aggregation, helping to connect and streamline your design and documentation workflows. Man and Machine prides itself on delivering honest guidance for its customers digital design requirements. From a simple 2D sketch to a complex engineering design solution it has the technical expertise and experience to deliver the right software and hardware to support your CAD needs.
Its services embrace: Technical Support - A range of levels to suit your budget and needs: from telephone support within guaranteed time lines to engineer call out contracts. Consultancy including design reviews, project management, license compliance, 2D to 3D process transition and best practice. CAD Training both scheduled courses and bespoke training. www.manandmachine.co.uk New Members: BEC Global Brunson Instrument GTW Developments Group Killala Precision Lonsdale Paragon Design Solutions Stocdon Succinct Solutions Tinius Olsen Triune Precision Engineering
Strong, loyal: Attention to detail at every stage and state-of-the-art Injection Moulding and Injection Mould Toolmaking facilities has helped Patterson & Rothwell (P&R) build a strong and loyal customer base across 25 industry sectors. Toolmakers of P&R's calibre rarely exist within an Injection mould company and its inhouse tool room commissions over 60 injection mould tools a year - all covered by the company's ground breaking 10 year warranty. With ISO 9001 and TS16949 accreditations P&R is quality conscious and system focused.
In-house Injection Mould Design incorporates Moldflow, the outstanding polymer prediction software package. The range of sectors covered has broadened the company's materials usage experience, from exotic materials for the defence industry to parts for automotive, white goods, electronics, packaging and construction. Its toolmaking skills, which stretch over 25 years, is coupled with investment in plant, personnel and training which allow P&R to compete successfully at the highest levels. www. patterson-rothwell.co.uk
IndySoft
Best supplier: IndySoft is recognised as a supplier of the best 'commercially available' Enterprise-wide range of gauge management, instrument calibration and tool management software tools on the market. The company constantly listens to customer needs and closely watches for changes in the market to stay ahead of the competition. This ensures its customers software is never out of date. With almost 20 years of continuous real-world development and thousands of global licence sales - IndySoft understands industry requirements, and specifically needs for compliance to standards including QS9000, TS16949, ISO9000, FDA 21CFR Part 11 and ISO 17025. It has customers across industry sectors including aerospace, automotive, medical, defence, food, electronics, rail, R&D, space and commercial laboratories.
A major advantage of using IndySoft software products is it gives you the benefits of years of feedback and pooled
Techni-modul Engineering
Composites innovator: Techni-modul Engineering has over 25 years experience in tooling, design and manufacture for the production of composite parts. It's expertise in various processing methods means it can define the best technology for your composite project. It was a finalist in the JEC 2011 Innovation Awards for its innovative development of a heating fluid circuit that optimises the thermal reaction of composite tooling. Among processes it is familiar
Werth Metrology
Quality Innovation: Quality, precision and innovation are the basis of success at Werth Metrology, part of Werth Messtechnik GmbH. With over 60 years serving industry the company has built an admired tradition in fine mechanics and optics. It has installed over 10,000 measuring machines in many industrial fields. Application examples include: aerospace engineering, automotive manufacturing, electronics, jewellery making, toolmaking, plastic injection moulding, medical technology, turbine manufacturing, and aluminium or plastic extrusions. It is a leader in coordinate measuring technology with optical sensors, multisensors and X-ray tomography, as well as in the measurement of micro features. Its product range extends from classic profile and measurement
with are RTM (Resin Transfer Moulding), Infusion, Thermoforming, Prepregs and Final Pressure Transfer Moulding (FPTM), which is an adaptation of the RTM and Prepreg technologies. It consists of injecting resin on preimpregnated fibres under pressure in a closed mould. Sectors served include aerospace, automotive, marine, energy, sport and leisure. The company is also a leader among machine builders, producing standard and special, made-to-measure machines to exact requirements including laboratory and thermoplastic presses; and compaction, cutting, preforming, control and injection machines. www. techni-modul-engineering.eu
projectors with standard solutions for optical 2D and 3D coordinate measurement technology, to highly-advanced coordinate measurement equipment with multiple sensors. The companys goal is to attain a high degree of customer satisfaction through world class technical solutions and unlimited user-orientation. www.werth.de
mould tooling development using additive layer manufacturing techniques in the Injection Moulding and Pressure Die Casting industries. His 33-year career has centred on tooling technologies. Originally a mould design apprentice with Metal Box, he has worked in roles including: tooling and moulding development with RPC, Technical Manager, DME (Asia/Pacific), UK management of hot runner companies and Business Development Manager, Jordans Toolmakers. Jon is interested in the development of new technologies in the Toolmaking industry. Bob Tunks, MD, BK Tooling Ltd: Bob served a formal apprenticeship in toolmaking
before moving into production engineering, a discipline that he strongly feels should be integrated with the toolmaking process. At 25, he was manager of a high pressure sub-contract toolroom; at 29 went into partnership forming a mould toolmaking company in Plymouth; and five years later in 1991 set up B K Tooling in Hertfordshire as a plastic mould toolmaking and moulding service, where he is developing a rapid tooling system which he sees as important for the future of UK toolmaking. He is strongly committed to promoting training of the next generations of UK toolmakers.
The event also saw a new President, Geoff Highley, and two new Board members: Jon Rackley and Bob Tunks. Tribute was paid to outgoing President Alan Pearce of SGS Carbide (UK) for all his work during his three years in office. Geoff Highley: Geoff was previously General Manager at McLaren Racing for nine years, and before that worked in various divisions of BAe. His background allows him to bring a different perspective to the GTMA. As he points out: Although I did run a toolroom at BAe, I have not worked as a toolmaker, or even within an SME. I am told this gives me the ability to
There were also two new Board members elected: Jon Rackley, Wolverhampton University: Jon has been involved in the Department of Engineering for five years, and is responsible for
ing bike frame legality, irrespective of where the measurement takes place. The scanner gives excellent performance even on high gloss carbon fiber surfaces and the difficult to reach areas typical of professional bike frames today. During measurement the integrated laser scanner collects 30,000 3D points off the frame every second, allowing the user to create a highly accurate 3D model of the frame itself. The
user can measure an entire bike frame, compare it to its respective CAD model and generate a final measurement report in less than ten minutes. Prof. Jan-Anders Mnson, Director of the EPFLs Laboratory of Polymer and Composite Technology, said the system helps to make sure the dimensions of racing bikes are completely above board, even during a race. www.hexagonmetrology.com
At the heart of
MANUFACTURING UK
New Series
GTMA - At the Heart of... Manufacturing UK is a new series to highlight the cross industry skills and experience of GTMA companies.
Buyer Resource
It will build into a resource for buyers and specifiers across all sectors, allowing them to find more easily companies with the products and services necessary to bridge supply chain gaps.
Case Studies
As well as Case Studies exemplifying best practice, At the heart of... will include A-Zs of relevant companies, many of them European and world leaders.
In this Section
Precision excellence at your service 12-13 What we do: Precision Engineering 13 A-Z: Precision Engineering 14 Erodex leads in EDM Moorland is an award Winner Aspin has knowledge Craftsman's big investment 15 16 16 17 Angstrom is innovative Press Tools - market leaders to serve you A-Z: Press Tools What we do: Press Tools 17 19-20 20 21 Stocdon has quality Roemheld helps UK ND Precision is excellent Bropel celebrates a lot 21 22 23 23
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Precision machining expertise in GTMA is across the full spectrum of manufacturing needs from micro machining through to large-scale projects exampled in this photo from member company Accura Geometric. Many members have sector-specific quality accreditations as well as ISO 9000 and environmental standards.
Well over 100 GTMA members carry out precision machining in-house when producing tooling for customers with many offering specialist services to non tooling clients. They include leading manufacturers of precision engineered
parts and special die mould bases to companies who specialise in delivering prototypes and low volume production parts. Precision machining is the backbone of much of the work our members do for their cus-
tomers, says GTMA CEO Julia Moore. It is also key to the help we can give major buyers in our priority sectors when they approach us to build strength in their supply chains. Many of our members are European and global leaders.
The precision machining resource within GTMA stretches right across industry sectors from aerospace and automotive, including Formula 1, through to medical devices, packaging, rail, marine, energy, defence and, of course, general engineering.
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Precision Machining
What we do
Expertise within GTMA covers a wide range of disciplines. Those listed here are a small sample of what is on offer using state-of-the-art equipment.
5-Axis Machining 5-Axis Milling Boring Deep Hole CNC Cylindrical Grinding CNC High Speed Milling
CNC CNC CNC CNC CNC CNC CNC CNC CNC CNC CNC CNC CNC CNC
Horizontal Milling Jig Boring Jig Grinding Machining Milling Precision Machining Routing Sheet Metalwork Sink and Solid Sink Sliding Head Turning Spark Erosion Turning Vertical Milling Wire Erosion
Cold Rollforming Tooling Custom Lapping Die Sinking EDM Drilling EDM Spark Erosion EDM Wire Erosion Engraving Fast Hole Drilling Form Grinding Free Access Cutting Gun Drilling High Speed Hard Metal Machining High Speed Milling Large CMM Inspection
Long Bed Grinding Micro EDM Machining Micro Machining Multi-Spindle Copy Milling Optical Profile Grinding Precision Machining Profile Grinding Prototype Machining Solid Sinking Spark Erosion Surface Grinding Thread Grinding Turning Vertical Milling Water Jet Cutting Wire Erosion
Photos courtesy (l to r): Erodex, Proto Labs, Waveney, Superite, Agie Charmilles and Aspin Engineering. Below: Craftsman Tools.
A 'can do' attitude is combined with commitment to investment in people and state-of-the-art equipment, which includes CAD systems, vertical machining systems, EDM systems, 4- 5- and 6-axis machines, and much more. The whole package from GTMA promises quality service and on-time delivery. It is the combination of traditional skills some members have been in the business for 50 or 60 years ! - and the latest design and engineering that results in outstanding performance and innovation. Skilled engineers and toolmakers work closely with customers and suppliers to ensure accuracy, precision, on-time delivery and above all excellence in quality. Complex machining to tight tolerances are second nature.
Members also have built up expertise in dealing with high specification aluminium, magnesium, titanium, stainless steel and a range of exotic materials; and there are members also who have worked in areas such as satellite microwave components, finished to microns in exotic materials. In-house experience often embraces areas such as surface treatments, including hand-finishing and polishing of hydraulic components. Many of the precision engineering companies are specialists in specific areas there are those with expertise in deep hole boring, EDM, prototyping, gun drilling, water jet cutting, profile grinding, and all kinds of finishing. Others are leaders in carbon and
graphite applications (including semi-conductor tooling); in zeropoint fixture systems, which are increasing the size of parts that can be machined; and in materials analysis. GTMA members are also aware of the need for practising environmentally-aware strategies (and have the Quality standards to prove it) and in the need for strict confidentiality. They are trusted suppliers where security is paramount. It is no surprise therefore that so many work within the aero-
space and defence industries, motor sport, packaging, medical and pharmaceutical and consumer electronics. Buyers requiring special precision machining can call GTMA on 0121 601 6350 for help in identifying the companies best suited to their needs, either direct or through the Manufacturing Resource Centre. www.gtma.co.uk www.manufacturingresourcecentre.co.uk Email: admin@gtma.co.uk
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3D Lasertec www.3dlasertec.co.uk Accura Geometric www.geometric.co.uk ADS Precision Tools Ltd www.plasticinjectionmouldtooling.co.uk Advanced Tooling Systems UK www.atsuk.com
Agie Charmilles www.gfac.com/uk Alphateq www.alphateq.co.uk Amtek Precision Engineers www.amtek-precision.com API Precision Toolmakers www.apiprecision.co.uk Aspin Engineering www.aspin-engineering.com Bedestone www.bedestone.co.uk Brafe Engineeering www.brafe.com Burcas www.burcas.co.uk Craftsman Tools www.craftsmantools.com CTL Engineering www.ctl-eng.com Cube Precision Engineering www.cubeprecision.com Delcam UK (Tooling Services Division) www.delcam.co.uk
Machine Tool Parts Manufacture Plastic Moulding Tools CNC Machining Thread Grinding of Plastic Moulding Cores CNC Turning Polishing and Universal Grinding CNC edm Wire Cut Machining Contact: Anton Aspin
Address: Unit 5, Egremont Close, Moss Lane Trading Estate, Whitefield, Greater Manchester M45 8FH Tel: 0161 766 9622 Fax: 0161 766 1423 Email: enquiries@aspin-engineering.com Website: www.aspin-engineering.com
EDS Engineering www.edseng.co.uk Erodex (UK) www.erodex.com Fenland RP www.fenlandrp.co.uk First Cut www.firstcut.eu FSG Tool & Die www.fsgtoolanddie.co.uk GB Precision Engineering www.gbprecision.co.uk Hadleigh Castings www.hadleighcastings.com Harper & Simmons www.harperandsimmons.co.uk Hanson Thorpe Precision Toomakers www.hansonthorpe.co.uk Hockley Pattern & Tool Company www.hockleypattern.co.uk Isomach www.isomach.com Thomas Keating www.terahertz.co.uk Kemet International www.kemet.co.uk Moorland Toolmaking Company www.moorlandtools.com N.D. Precision Products www. ndprecisionproducts.co.uk Newcastle Tool & Gauge www.ntg-ltd.co.uk DG Mortimer & Co www.ukplasticmouldings.co.uk PDQ Engineering www.pdqengineering.com Phoenix Engineering 2009 robin.rapley@phoenixengineering2009.co.uk Playden Tools playden.tools@btinternet.com
Powell Manufacturing Tel: 024 7668 5131 Fax: 024 7663 7886 PP Injection Moulds www.ppmoulds.co.uk Proto Labs www.protolabs.co.uk www.protomold.co.uk www.firstcut.eu/gb Quick Tools www.quicktoolsltd.co.uk Ryetools www.ryetools.co.uk SGH Moulds www.sghmoulds.co.uk Shield Engineering www.shield-eng.com Smithstown Light Engineering www.sle.ie Solent Mould Tools www.solentmouldtools.co.uk Superite www.superite.co.uk Tokai Carbon Europe www.tokaicarboneurope.com TRAC Heaton www.trac-group.com TRAC Precision Machining www.trac-group.com Tremic Tools www.tremic-tools.co.uk Unijig www.unijig.co.uk Waveney Precision www.waveneyprecision.co.uk Whiteland Engineering www.whitelandengineering.co.uk Wines Group www.winesweb.com
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S P ECIALIS TS IN
An electrode-led design process has become the focus for Dorset-based BWP Technical Services, part of the Erodex (UK) Group. BWP specialises in project managing a one-stop shop solution from design to manufacture of work-holding and lifting solutions for complex and precision parts, especially in the aerospace sector. Too many companies, it says, make the mistake of having a tooling-led approach to the design process for EDM, rather than an electrode-led design process. The design and performance efficiencies of electrodes are too often sacrificed because the holders are designed first, said BWP Director, John Rolinson. The key is to design the electrode first, then design the holder to correctly fit the electrode with a dedicated tooling solution. It is the electrode that does the work, and is process critical not the holder. This process, combined with
approved toolmakers and guidance from Erodex which is one of the market leaders in EDM electrodes for aerospace applications, is the key to success. Its choice of toolmaker is also crucial often bringing reduced project costs and lead times by splitting a tool or suite of tools between several companies. Recent successes include EDM tooling for aerospace clients in the UK and US; a large blisk handling solution for a leading aero engine producer; and a safety-led lifting project driven by the need to separate operators from aggressive acids used in aerospace production. In all cases, BWP provided innovative, robust and cost effective designs which met or exceeded project parameters. This commitment to excellence is paying dividends, with the company seeing 58 per cent growth in turnover year on year and a strong customer base in the aerospace sector. www.bwptech.co.uk
15
Precision Machining
from small precision multi-cavity components to suites of tools up to 10 tonnes. The company offers a complete manufacturing facility to cater for all general engineering requirements. Specialist services include: Sub-contract machining Jigs and Fixture work 1 off's to multiple batchwork Spark Erosion Wire Cutting
Deep Hole Drilling 3D Machining CNC Milling CNC Turning Laser Welding Service
As well as precision machined components manufactured to fine tolerances, short lead times, and with personal service, Moorland also offers a full refurbishment service for injection and compression mould tools. www.moorlandtools.com
16
Precision Machining
Craftsman Tools managing director Robert Johnson (right) and business development manager Tim Thorburn with new products in the companys new extension.
sion engineering tasks, with continued investment in the latest design techniques, state-ofthe-art machinery and plant maintaining industry leadership. Other recent products include Split Boring Bar Holders, providing excellent vibration
absorption, deeper boring capability and improved stability during machining; and a portable hardness tester for onsite components inspection, developed in partnership with Cameron USA. www.craftsmantools.com
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ND Precision Products
Toolmakers / Precision Engineers Mould Tools Press Tools EDM/Spark Erosion WEDM (Wire Erosion) High Speed Milling Electrode Design Jigs & Fixtures
We offer an exceptional service for precision specialist welding of plastic injection, pressure die casting and press tools.
Fast Turn Around - while you wait or next day Laser Welding Tig and Micro TIG Welding Onsite Welding - Fast Call Out Collection and Delivery up to 500kg within 25 mile radius Reliable courier service for customers further afield Flame Hardening Welding of all Tool Steels, Aluminium, Stainless Steel and Cast Iron Batch & Repitition Welding Handling Capacity up to 10 Tonnes
01271 345496
info@ndprecisionproducts.co.uk www.ndprecisionproducts.co.uk
Darren Cook or Sue Lloyd - Tel: 01922 745745 On site Welding: Neil Baggott: 07866 611235 www.bropel.co.uk Email: welding@bropel.co.uk Tel: 01922 745745 Fax: 01922 745746
Press Tools
Press tool companies in the GTMA really are At the Heart of Manufacturing UK, with members serving leading companies across many industry sectors. The skills and experience we have is second to none, says GTMA CEO Julia Moore. Many of our members lead in Europe and the work they do is often ground-breaking and the solutions they implement are sometimes among the most innovative in the world. As an organisation we are UK leaders in tooling and our Toolmakers' Forum is bringing even more focus to the help we can give manufacturing supply chains.
The pedigree of GTMA press tool companies is at the leading edge of the sectors they serve right across industry. GTMA companies are leaders in their chosen markets from aerospace and automotive to packaging, nuclear, defence to investment casting and Gas Turbine industries. At the heart of GTMA Press Tools are people skills and investments in state-of-the-art equipment. Member companies are some
of the best equipped press tool manufacturers in the UK and Ireland with policies of continuous improvement and accreditations. They are committed to give their highly skilled workforces the means to achieve excellence. It has paid off with healthy order books and globally recognised respect. For example Crossen Engineering in Northern Ireland has been working with the worlds leading gas turbine company in the US to develop a new method of producing aero engine air seals. Instead
of being rolled they are pressed using a tool machined by Paul Crossen. A further press tool aerospace project was to design a press tool for forming a sector of engine nacelle lip skin from a sheet metal blank, currently aluminium but looking to titanium for the future. The prototype was exhibited at the Paris Airshow. Often the investment in new machinery and technologies has a direct impact on cost effectiveness as the productivity gains
are passed on to customers. Across the membership there has been spending on an extensive and diverse range of large capacity technology. From small mock-up tools to large tooling suites, Cube Precision Engineering has the capacity to project manage and manufacture a wide range of tooling for the aerospace, automotive and white goods industries With machining capacity up to five metres and lifting capacity
continued on page 20
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Press Tools
A-Z of companies - Press Tools
GTMA members in the current Buyers Guide serving Press Tools are listed below with the strength of their expertise very wide. It covers not only manufacture, often in specialised areas, but also services such as press tools trials and the supply of standard parts and components. Please call GTMA for more information on 0121 601 6350 or email: admin@gtma.co.uk PRESS TOOLS MANUFACTURERS Accura Geometric www.geometric.co.uk Angstrom Engineering www.angstrom.uk.com API Precision Toolmakers www.apiprecision.co.uk Bedestone www.bedestone.co.uk Bruderer UK www.bruderer.co.uk Casting Support Systems www.cssltd.info Crossen Engineering www.crossengroup.com CUBE Precision Engineering www.cubeprecision.com Delcam (Tooling Services Division) www.delcam.co.uk EDS Engineering www.edseng.co.uk Erodex (UK) www.erodex.com FSG Tool & Die www.fsgtoolanddie.co.uk Harper & Simmons www.harperandsimmons.co.uk Hockley Pattern & Tool www.hockleypattern.co.uk Isomach www.isomach.com Thomas Keating www.terahertz.co.uk Moorland Toolmaking www.moorlandtools.com N. D. Precision Products www. ndprecisionproducts.co.uk Portway Tool & Gauge www.portwaytool.co.uk Powell Manufacturing Co powellmfg@btconnect.com premiermouldservices.co.uk Shield Engineering www.shield-eng.com Surface Generation www.surfacegeneration.com Toolrite www.toolrite.co.uk
Photo courtesy WNT (UK) a GTMA member with over 45,000 items of tooling in its catalogue. It is listed under Special purpose equipment on the website.
Quick Tools www.quicktoolsltd.co.uk Waveney Precision www.waveneyprecision.co.uk PRESS TOOLS SERVICES 3Dnorth CADCAM Services www.3dnorth.co.uk Dutton Simulation www.duttonsimulation.com FSG Tool & Die www.fsgtoolanddie.co.uk Harper & Simmons www.harperandsimmons.co.uk Thomas Keating www.terahertz.co.uk Mouldtech Solutions www.mouldtechsolutions.com
N. D. Precision Products www. ndprecisionproducts.co.uk Strand www.strandeng.com PRESS TOOLS Standard Parts/Components Boneham & Turner www.boneham.co.uk Bruderer UK www.bruderer.co.uk Dayton Progress www.daytonprogress.com Talbot Tool Co www.talbot-tool.co.uk Unijig www.unijig.co.uk
up to 35 tonne, its tryout facilities up to 1000 tonne offer a viable alternative to home line presses for tryout and emergency breakdown back-up. The company are specialist press tool makers so whether it is for automotive body sides, a class 'A' panel for interior running boards or dashboards, or even the front strutted case for the latest medium range aircraft, Cube Precision has the experience and knowledge. Another leading company is Accura Geometric which recently added 2.5metre surface grinding to its varied list of manufacturing capabilities
which includes 5axis machining, large milling, EDM and component prototyping. The ability to provide all this inhouse has seen it expand its traditional offering of press tool manufacture into new sectors including the chemical, motor sport and power generation industries, taking employee numbers above 70. However aerospace now represents 40% of sales. To achieve this Accura adapted its toolmaking skill set and knowledge of manufacturing methods to this industry. It now both manufactures the tools for pressing aero engine components in high
Single operation form tool for off-road vehicle panel images courtesy Accura Geometric
temperature materials and produces complete processed parts, delivered in Kits, ready for assembly, to a Kanban scheduling system. A recent project included the manufacture of a complete set of engine parts, necessitating low volume pressing, 5-axis milling, wire erosion and 5-axis laser cutting. To support all
this Accura has gained AS9100 and Nadcap (EDM) accreditations. Finally, there are specialist companies in the supply of Press Tools Standard Parts and Components, including Dayton Pogress the world's largest manufacturer of consumable precision press tool components and accessories.
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Press Tools
What we do
Here are just some of the press tools manufactured by GTMA members, along with a small cross section of press tool services and the many hundreds of standard parts and components supplied. MANUFACTURE: Automotive Panel Tools Blanking Tools Canning Tools Cold Forging Tools Combination Tools Compound Tools Deep Drawing Tools Extrusion Tools Fine Blanking Tools
Foil Tools Forming Tools Hot Forging Tools Laminate Tools Panel Tools Piercing Tools Progression Tools Tungsten Carbide Progression Tools Pin Tooling Technology Press Tools Press Tool Modification Press Tool Repair Press Tool Servicing Press Tool Spares Prototype Pressings Punch Press Tools Reverse Deep Drawing Tools Semi-Conductor Tooling Silicon Carbide Semi-Conductor Tooling
Subtractive Pin Tools Transfer Tools Tugsten Carbide Lamination Tools Warm Forging Tools SERVICES Analysis and Design Blank Development Component Development Press Tool Design Press Tool Trials Progression Tool Design STANDARD PARTS / COMPONENTS Aluminium Die Sets Cam Piercing Units Clevis Pins Custom Die Sets Gas Springs
Gas Spring Manifolds Grinding Long Beds Grinding Surface In-die Tapping Units Jig and Fixture Products Pillars and Bushes Press Tool Feed Equipment Punch and Dies Sealing Plugs Shims Steel Die Sets Stripper Bolts Tapping Units Tooling Aids Urethane Parts for Press Tools
Photos courtesy (l to r): Erodex, Proto Labs, Waveney, Superite, GF Agie Charmilles and Quick Tools
gramme ever seen of standard products, with quick delivery, too, and the best prices in the UK, with plug gauges less 20% and ring gauges less 45 50% of market prices. Stocdon are proud to be associated with JBO, and consitently supply the very best in thread gauges, thread milling tools & dies. www.stocdon.co.uk
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Press Tools
makes components for hydraulic wrenches, including main bodies from TWS17N and TWH27N up to TWS100N and TWH120N, plus JAS Jacks and many other high volume small components. Hi-Force Workshop Manager, Paul Dutton, said: We were very impressed with the performace of a Hilma MC125Z vice which was previously fitted on another Mori Seiki machine. This vice has been working across two shifts for two and a half years and it has maintained full accuracy despite both jaws moving. So Roemheld was an obvious choice when we were looking to fit further vices on our new machine. He said Hi-Force is so pleased with their quality and reliability that it plans to fit at least two more Roemheld vices as it expands its machine shop capabilities. The company produces over 1700 products and specialises in high volume production. It exports 87% of its products to over 100 countries in sectors including Oil & Gas, Petrochemical & Refining,
Power Generation, Steel & Aluminium Plants, Paper Mills, Sugar Refineries, Railways, Mining, Construction, Ship Building & Ship Repair, Aerospace, Defence and Heavy Engineering. Group Managing Director, Kevin Brown, said Hi-Force is committed to manufacturing products of the highest quality, using the best machinery available, to ensure its products meet the most stringent quality requirements possible and yet retain a competitive price in its global markets. That is why we only work with quality tooling suppliers, such as Roemheld, he said. Roemheld is committed to researching and developing products designed to meet not only the demands and expectations of todays discerning buyer, but also emerging markets and applications. Through continued improvement of products and services, the Roemheld Group intends to remain an innovator at the forefront of technology. For more information call 0121 453 1414 or visit the website. www.roemheld.co.uk
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Press Tools
The combination of this wealth of experience and investment in sophisticated machinery and software ensures demand for their
After 40 years experience Bropel Technical Welding celebrates its 2nd anniversary !
Bropel Technical Welding is celebrating its second year of full trading 40-plus years after the seeds were born for the company, which has huge expertise in the toolmaking sector. It was formed in September 2010 on the reorganisation of what was previously Bropel Specialist Welders (founded 1969). Since then Bropel Technical Welding has made a big impact in the sector and, says MD Sue Lloyd, daughter of the original Bropel founder John Higginson Snr, its success in its first two years is down to a fantastic team. Many of these have worked with Sue for over two decades and their expertise helped the new entity to ISO 9001 accreditation within 18 months. We basically went back to our routes, she said. We have achieved an enormous amount in these two years and have a very loyal customer base. I am very proud of what the team has done. At the heart of the company is its core skills including: Laser Welding with over 10 years experience its laser team are among the leaders and the fastest - in the sector. The process is used to repair and modify tools and dies. TIG and MIG Welding the original company were pioneers and this tradition of high level service continues to provide quick and efficient solutions to industry. It is often used for larger repair areas. Tool Repairs specialists in modification and repair of
tools, with minimum downtime in your production. This includes on-site service within 24 hours when required. Bropel Technical Welding are
always happy to discuss your specific requirements. Please call 01922 745745 or email: welding@bropel.co.uk www.bropel.co.uk
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Machine Vision in The Production Environment Brian Castelino, MD, Machine Vision Technology. In a very hands-on presentation Brian demonstrated live a machine vision system to demystify the technology and give examples of its use. Brian is one of the most experienced people in the UK in the field having been involved in the technology since it emerged here in 1985. Today, it is found throughout industry performing high speed inspection and non contact measurement. Yarn splicers and the composites industry Graham Waters, GTW Developments Group. In the textile industry yarns need to be joined together at some stage of production and traditionally were knotted. Now pneumatic yarn splicers are virtually universal in textiles to make joints which are smooth, strong, and unobtrusive. But pneumatic splicers are largely unknown in the composites supply chain. Graham looked at the problems and how new splicers have been developed for composites. Vortex Machine DNA Steve Creron, Delcam Steve, now responsible for all UK sales activities for Delcam, joined the company in 1985 and toured the UK as part of the then DTI sponsored road show promoting CADCAM to UK industry for two years. Prior to that he was with General Motors. He was part of the management team that purchased Delcam from the Delta group in 1989 and was appointed General Manager in 2008. His presentation covered Vortex high-speed roughing.
The presentations included: The best way to predict the future is to create it Steve May Russell, Smallfry Steve is a graduate in Industrial Design and Engineering from Leicester De Montfort University. Following a condensed MBA at Warwick University he studied consumer marketing under renowned 80s marketing guru Philip Kotler at the JL Kellogg Graduate Management School in Chicago. He has worked with blue chip companies worldwide including Boots, Unilever and GSK and represented the creative industries on the UK Trade & Investments bi-lateral partnerships in the Far East. The focus of his presentation was on how to realise opportunities you have yet to imagine. To inspire a business effectively you need a bold compelling vision. Created Futures is for business leaders and senior management teams looking for insights, business cases and hands-on experience to inspire teams and deliver tangible outcomes. Visionaries conceive and embrace a world ahead to imagine the way things will be and the way people will want to live. His presentation looked at how leadership can help teams be more creative, entrepreneurial and have greater confidence.
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A Global Perspective on the uptake of DMLS for Production Tooling Stuart Jackson, UK Manager, EOS Electro Optical Systems Although DMLS (Direct Metal Laser Sintering) Tooling has been around for many years uptake has varied greatly. Stuart showed why and where DMLS has succeeded, and gave a future perspective of expected growth and technical developments. EOS is the world-leading manufacturer of laser sintering systems used for rapid prototyping, rapid tooling and rapid manufacture. Laser sintering is the key technology for e-Manufacturing, the fast, flexible and cost-effective production of parts directly from electronic data.
Resource-efficient high value net-shape manufacturing using powders Dr Moataz Attallah, lecturer in advanced materials processing at the School of Metallurgy and Materials, University of Birmingham. The use of powders is a resource-efficient approach to produce complex net-shape structures, with potentially low buy-to-fly ratios and much reduced materials waste. compared to other manufacturing processes. Challenges of net-shape manufacturing include improving productivity to produce high throughput technologies, securing the supply chains for powders, and the development of process modelling capabilities. Dr Attallah summarised the key issues.
Research and Technology Developments in the Machining and Advanced Aerospace Materials Dr Sein Leung Soo, School of Mechanical Engineering Leung is currently Head of the Machining Research Group at Birmingham University, which is widely regarded as a centre of excellence in its field. He explained how engineering materials used in high performance aerospace applications such as gas turbine engines and aircraft structures are typically characterised by advanced physical/mechanical properties such as high strength to weight ratios, large stiffness modulus or the ability to operate under extreme temperatures and loads. Despite aspirations for netshape manufacturing, machining operations remains a key process for both roughing and finishing of components in aerospace. The presentation gave an overview of current research into the challenges associated with the machining of advanced aerospace materials such as nickel based super alloys, titanium alloys and carbon fibre composites from the perspective of workpiece integrity. Some of the latest developments in new innovative processes to improve machining efficiency and flexibility were also covered.
Daniel Lainchbury, Physical Digital The presentation dealt with the 3D scanning of the last remaining Mk11a Spitfire that saw service in the Battle of Britain: How the company conducted the scan, the processes involved in scanning such a large object, and downstream applications for the data (See GTMA Issue 1/2012). The company was called in by Amalgam Fine Model Cars who needed the digital data to create a highly accurate scale model. Physical Digital used a combination of photogrammetry and three systems which were used to capture the data: GOM TRITOP, GOM ATSO and GOM Touch Probe.
Hot desks at the event were manned by Birmingham University, Delcam UK, EOS, ES Technology, Fenland RP, GTMA, GTW Developments, HR4 UK, Renishaw, SFJ Systems, SGS Carbide Tool, Starrag UK, Steinbichler and Vero Software.
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automotive
Special
GTMA recently hosted a special automotive event with Vero Software featuring advanced materials and processes.
Supply Chains
CEO Julia Moore told delegates there was a need for supply chains to be supported.
Best Practice
The programme saw a range of presentations highlighting manufacturing best practice in a sector employing around 130,000 in the UK.
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implement automation. The UK Automating Manufacturing Programme provides awareness and education about the benefits of robots and automation, along with expert support and financial assistance. For further information go to www.automatingmanufacturing.co.uk. With the event held at Agie Charmilles Technology Centre, the machine toolmakers Product Manager Steve Burrows said the main benefits of the linear motor technology which features in their machines, are accuracy, surface finish, and repeatability. We have seen a ten-fold improvement in surface finish over two years, with linear motors. Dr Per Hansson, SSABs Tooling Product Manager, said die making manufacturing time had been reduced by 32% using pre-hardened tool steel. He gave an example where pre-hardened tool steel was used to make the tools for the stamping of 1.8mm 600DP, and the tool manufacturing time was reduced by two weeks.
Vero Marketing Manager Marc Freebrey demonstrated VISI tools which compensate the original CAD geometry by a precise amount at pre-production stage to achieve the desired form. These steps use the difference between the original CAD data and the mesh analysis to change the relevant parts of the geometry to adequately compensate for springback once production starts. Other topics included Chris Buxton, CEO of the British Automation and Robot Association, explaining that Government grants are available to help companies
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automotive ...
ISO9001:2008 Certied
Photos from the GTMA Auto Event held at member company Agie Charmilles' Coventry facility. Hot desks, left, and the Manufacturing Resource Centre stand. Left, bottom, Marc Freebrey, Vero Marketing Manager. Vero cohosted the event and Marc demonstrated VISI tools.
1-10
ProtoQuote
Another benefit is its stability and strength. A company using prehardened steel for the tools to stamp 1mm 400DP found the die displayed no visible wear after stamping 1.6 million components. Developments in low cost sheet metal processes were demonstrated by Roger Onions, Business Development Director at the MRC. He said low tooling costs and reduced lead times, along with high tolerances and level of detail on parts, meant Incremental Sheet Metal Forming was becoming increasingly popular over traditional press tools for manufacturing low volume body parts in the automotive, aerospace, rail and marine industries. ISF is also popular for repairs in aftermarkets, architectural features, signage, personalised or customised products and medical plate inserts. SMIRT software, from Vero is a manufacturing process management tool designed specifically for the Die Build stamping industry. Cosimo Galante showed how it integrates with design data giving an effortless and clear 3D representation, reducing errors, leading to overall improved data management. Best practices are captured and made available as a template for use in future projects. The event was rounded off by Mike Richards, Managing Director of press toolmaker Accura Geometric. In his overview of the toolmaking industry, he said the sector was now in a positive period of high activity, after ten years of UK manufacturing outsourcing presswork, which saw toolmaker numbers reduced by 60%. UK toolmakers, he said, need to demonstrate the total life cycle cost savings of British-made tools compared to those from abroad, and challenge the willingness of customers to accept inferior overseas products. www.gtma.co.uk www.verosoftware.com
Part production
Visit www.protolabs.co.uk/parts today to get a FREE Prototyping Processes Whitepaper. Enter source code Code EUGT12
Call +44 (0) 01952 683047 or visit www.protolabs.co.uk
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Images, courtesy of Dutton Simulation, which highlight some of the modules making up FTIs FormingSuite software. It brings huge cost savings in vehicle panels by upfront analysis to optimise cost, manufacturing and product function. Above is the new ProcessPlanner which goes a stage further by developing the process for the part. mately calculates the tool cost and is a technology recently adopted by BMW. Getting it right at the start influences costs enormously and Trevor emphasised the importance of upfront analysis to optimise cost, manufacturing and product function. In the presentation Trevor looked in detail at blank development, where special blank prediction software calculates the minimum blank size from a 3D CAD model. The method is fast, accurate and widely adopted throughout industry. The best material yield for sheared blanks, nested coil or progression strip layouts are calculated using blank nesting and progressive die nesting software. A key issue with the method is that material cost is based on CAD only. It confirms programme budgets at each gateway, and provides reliable benchmarks to review supplier quotes. While raw material dominates the Total Part Cost, both Process and Tooling costs are also needed: Process Cost takes account of the number of operations to make the part and factors such as whether manual or automated press facilities will be used. Tooling Cost calculations are based on size, number required, type (direct vs cam operations) and other factors such as location. ProcessPlanner uses process templates based on legacy methods. All features must be assigned to an operation and tool
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development process. FASTFORM Multistage allows upfront analysis of parts that are not formed in a single operation: the system needs to track strains between operations, and develop trim lines between forms. The FTI Multistage solver produces fast solutions allowing an iterative approach to process design. Solution times for complete sequences can be under one minute. At a later stage, incremental analysis become more important. FTI FAST Incremental stamping analysis (e.g., based on LSDYNA) is the most accurate simulation tool but requires tool design data to operate particularly for wrinkling prediction. Therefore a method is needed to automate tool creation from final form geometry, and Dutton uses the Auto Generate function in FAST Incremental for this. Part tool geometry is created including punch, blankholder and die. Simplified user interfaces enable non FEA specialists to apply the method as there is minimal effort to create required input data. Benefits of this modular approach include early analysis of part formability using inverse methods for fastest calculation, as well as the ability to use incremental methods earlier in the tool development phase. Springback Compensation Incremental solutions, said Trevor, also allows Dutton to consider one of the biggest remaining challenges springback calculation and, especially, tool compensation for springback. Springback causes geometrical fit and function problems but also causes cosmetic problems which are critical for outer panels. By calculating the deviation from the required shape we can apply this in reverse to correct the tool, he said. The method is iterative and once prediction is within tolerance we can map the modified CAE model to the CAD data. www.duttonsimulation.com
cost calculations are again - based on CAD data only. The system offers customisable cost formulas and reports. Part cost data reports are used as benchmarks to check part cost vs. budget for each part and these highlight outliers for further analysis. Reliable benchmarks like these help to review quotes from suppliers. Cost contours Every part, of course, has critical nest points which control the pitch and width dimensions. Optimising the shape (contact) of these points yields higher material use, and if engineering changes are made, it is very important to know if the changes are in the free material zone or at a critical nest point. Trevor showed how cost contours are used to highlight critical contact points for part modifications to save material with these contours on both the blank and the part. Once again a key benefit is that the cost optimisation is based on CAD data. The information flow of the system not only improves material use and design efficiency but also gives immediate feedback to part design. Automated Material Utilisation Analysis takes place by exporting from the vehicle model data the part geometry (batch process from V5 to IGES) to the FTI costing system. This checks design efficiency and when it is not acceptable the parts are reviewed using the FTI CostOptimizer in Catia V5. Part
changes to improve efficiency are identified and the changes confirmed as acceptable for all functions. Only then is the design database updated. Forming Feasibility Trevor also explained methods used for upfront analysis to establish manufacturing feasibility. This covered issues including: Formability Splitting Wrinkling/Loose Material Excessive Thinning Processing Trimming & Piercing considerations Number and type of forming operations required and Forming force required Depth of Draw Dimensional Control (Springback Compensation) The full feasibility assessment, therefore, requires consideration not only of the geometry and material but also the intended manufacturing route (press line size and force constraints, number of forming stations, etc). In the presentation Trevor looked in more detail at 'Formability' where FASTFORM formability analysis software is used. Failure criteria on a Forming Limit Diagram show the effect of thinning of material, highlighting when wrinkling limits are exceeded and where there would be splits. The automotive sector needs different analysis methods at different stages of the
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Proto Labs design reviewing system also played a very important part in the early stages of the design process. Credited by Nebulem as getting everyone on the same page, the company claimed it worked extremely well throughout the TouchClone development phase and allowed the project to be managed simply from start to finish. Nebulem, which has a history of successful collaboration with Proto Labs, says it acts as a vital link between clients and Proto Labs services where projects require product design expertise. TouchClone, with volumes likely to be hundreds-off, or low thousands, was due to be in production as we went to Press. www.protolabs.co.uk www.nebulem.com)
precision collet chucks, with a guaranteed runout accuracy of 3 micron. The chucks and the new OZ style collets allow users of cutters with shank diameters between 16
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Select Moulds offer a wide and diversified product range to its customer base, including: Automotive Electrical (Switchgear) Medical (Devices, Respiratory) Telecom (Connectors, Mobile Phone) White Goods Aerospace (High Accuracy one-off Machining) Repair and Refurbishment (All ranges of moulds, Non Select Products, Prototype Moulds, Rapid Tooling, Soft Tooling) Pre-Production Tooling (Fully Hardened Production Simulated Moulds) Multi-Cavity Moulds Gas Injection Multi-Shot Moulds Full Turn-Key Packages
From single impression soft prototype tools to high volume fully hardened multi cavity tooling
For more information contact Simon Collins on Tel: 01494 686820 Web: www.selectmoulds.co.uk
www.moultechsolutions.com
ADM Precision Tools Ltd is one of the UKs premier toolmaking companies specialising in injection and blow mould tooling design and in-house manufacturing. Investment in advanced equipment and a highly skilled team gives our customers an extremely competitive edge to their technical requirements.
Our Industry Portfolio includes: Electronics - Medical - Electrical Consumer - Security - Packaging Cosmetic - Dairy - Food and Drink - Household - Automotive Car Care. Injection Mould Tooling, Two Shot Mould Tools, Blow Mould Tooling, Repairs and Modifications (Capacity up to 5 tonnes). Tooling Repair Aftercare Preventative Maintenance Tool repair and modification work carried out on a 24/7 basis when required. Tooling Trials All our moulds are trialled at our sister company. www.AllianceMouldingServices.com Quality Approvals: ISO 9000 series Tel:0161 872 8881 Fax:0161 872 8883 Email:jimkelly@adm.eu.com Website: www.adm.eu.com
B K Tooling
B K Tooling is a specialist in the design and manufacture of rapid tooling for low to medium volumes of plastic injection moulded products.
B K Tooling Pleasant View Gaston Green Bishops Stortford Herts CM22 7QS Tel: 01279 600970 Fax: 01279 600980 Email: bob@bktooling.co.uk Web: www.bktooling.co.uk
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World Leader in Coordinate Measuring Machines with Optics, Tomography, Multisensor System
MMM 2012
Impressive
GTMA's Make Measurement Matter Roadshow is all set to go with an impressive line-up of exhibitors and speakers.
Showcase
This year's event at the Centre for Engineering and Manufacturing Excellence in Rainham will once more be showcasing new products and upgrades from member companies.
Technology
It is evidence again of how highly regarded MMM has become as it focuses on technology transfer.
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ous attendaces. Among these is Alicona, the non-contact 3D measurement specialists. We will be exhibiting at the MMM roadshow for the fourth time and it is an event that Alicona considers very important in the exhibition calendar, said Sales Director, Brian Kyte. It will be showing, for the first time at this event, the
InfiniteFocus SL system, which is based on the well established focus variation technology and allows quick and easy measurements in a manufacturing and laboratory/measurement room environment. Many GTMA members are taking the opportunity to show new products or upgrades including:
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Bowers Metrology: demonstrating the completely new integral digital readout feature on its compact two-point MicroGauge bore gauging system, which is designed for accurate measurement of bores from 1 to 6.00 mm. FARO Technologies: launching the new Vantage, a true laser tracker that combines disruptive new features and a supremely portable design. Dramatic reductions in size and weight make the device extremely portable.
Mahr: giving a world premiere for its innovative measuring system MarSurf One which combines Mahr technology with the comfort of a Smartphone. The premiere offers advantages to manufacturers at affordable prices. Phase Vision: exhibiting a range of new, innovative non-contact 3D measurement solutions for manufacturers. Phase Vision, says these new options offer industrial users competitive advantage through improved inspection capability.
Verisurf: the metrology software development company committed to delivering advanced computer-aided inspection and reverse engineering solutions, is demonstrating its brand new X6 product. The new X6 is loaded with
innovative features that greatly expand the capability of metrology devices, says Verisurf president, Ernie Husted. www. makemeasurementmatter. com
Exhibitors
3D Scanners UK www.3dscanners.co.uk Specialist 3D scanning services Alicona UK www.alicona.com Non-contact optical 3D measurement ATS Quality Products www.ats-global.com Advanced metrology and data collection Blum Novotest www.blum-novotest.com In-process metrology solutions Bowers Metrology Group www.bowers.co. uk Precision measurement equipment Brunson Instrument www.brunson.us Laser tracker accessories etc BTMA www.btma.co.uk British Turned Parts ManufacturersAssociation Conway Precision Engineering Group www.gauges.co.uk Mechanical engineering, fixturing, tooling & gauging Creaform www.creaform3d.com 3D scanners, measuring systems
Delcam UK www.delcam.com Inspection software Europac 3dimensional www.europac3d.com 3D scanning systems, portable systems etc Faro UK www.faro.com/uk Coordinate measurement devices and software GOM UK www.gom.uk.com High-end measuring system solutions Heidenhain (GB) www.heidenhain.co.uk Linear, angle and rotary encoders, digital readouts etc Hexagon Metrology www.hexagonmetrology.com Comprehensive metrology product range IMSM www.imsm.com ISO specialists for industry Indysoft Europe www.indysoftco.uk Metrology, tool management and calibration software Mahr UK www.mahr.com Production dimensional measuring technology Metrology Direct www.metrology-direct.com Measurement and inspection solutions
Micron Metrology 2000 Limited www.micronmetrology.co.uk Leading EU UKAS calibration laboratory Marposs www.marposs.com Global supplier of precision metrology equipment Nikon Metrology UK www.nikonmetrology.com Innovative metrology and vision measurement systems NPL National Physical Laboratory www.npltech.co.uk Centre for measurement standards Phase Vision www.phasevision.com 3D shape measurement systems Physical Digital www.physicaldigital.com Service bureau / Reverse Engineering Piccadilly Precision Engineering www.piccadillyprecision.co.uk Specialist gauge manufacturers Renishaw www.renishaw.com In-process measurement systems Solartron Metrology www. solartronmetrology.com Measurement transducers and instrumentation.
Spectrum Metrology www. spectrum-metrology.co.uk Measurement solutions including electro-optical Steinbichler UK www.steinbichler.co.uk Leader in optical measuring and testing technology Taylor Hobson www.taylor-hobson.com High precision specialists in surface, roundness and form measurement Third Dimension www.third.com Non-contact optical metrology system Tinius Olsen www.tiniusolsen.com TRAC Measurement Systems www.trac-group.com Inspection, testing services and equipment Verisurf UK www.verisurf.com Metrology software development Vision Engineering www.visioneng.com Optical systems Carl Zeiss www.zeiss.co.uk/ metrology Coordinate measurement machines
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measurement and visitors to MMM can discuss their applications on the Spectrum stand. The company are specialists in electro-optical metrology, surface roughness, roundness, contact and non-contact metrology applications and are agents for Taylor Hobson (workshop
surface finish/roundness, Alignment, Angle and Level), FARO (Gauges) and Brunson (laser tracker accessories). Full details on the website or call 0116 2766262. www. spectrum-metrology.co.uk
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With more than 20 production facilities and 70 Precision Centers for service and demonstrations, and a network of over 100 distribution partners on ve continents, we empower our customers to fully control their manufacturing processes, enhancing the quality of products and increasing efciency in manufacturing plants around the world.
services for all industrial metrology applications in sectors such as automotive, aerospace, energy and medical. We support our customers with actionable measurement information along the complete life cycle of a product from development and design to production, assembly and nal inspection.
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MMM 2012
for refining or completing clay models a requirement for creating automotive and marine styling models. The combination of a dual-column CMM and PowerINSPECT enables inspection times to be reduced by allowing the simultaneous measurement of different features on larger parts. A common application is automotive body-in-white inspection,
where the evaluation of a large, complex and relatively symmetrical assembly requires intricate measurements on each side, combined with an assessment of the structure as a whole. Using this new module gives the ability to measure parts on these devices in a single coordinate system without repositioning. www.delcam.com
were looking for an advanced internal measuring system that would increase our gauging capability and allow us to further control our process. The pressure exerted by many of the available measuring systems precluded their use on our products, as they are liable to deform some of our thinner walled plastic components. To help overcome this problem, Bowers was able to reduce the spring pressure of its Digital Pistol Grip XT Bore Gauges and to retrofit a depth stop to speed-up operation. In fact, Bowers understanding of our requirements and willingness to adapt its standard products to our needs, led Bowers to suggest the fitting of
wireless modules to our new gauges, enabling the sending of measured data without the need for a physical link. Now in contant use, the adapted Bore Gauges have proved a great success and are making an excellent contribution to guaranteeing the continuing quality of our output. Bowers Metrologys state-ofthe-art XT Xtreme Bore Gauging range boasts advanced electronics that have an impressive IP65 rating. This renders them resistant to coolant, water and airborne particles and makes them ideal for use within hostile measuring environments, such as near to Machine Tools. www.bowers.co.uk
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u r m e t e r | p a r i s | 1791
SURFACE METROLOGY
Mahr U.K. Plc - 19 Drakes Mews, Crownhill, Milton Keynes, MK8 0ER, GB www.mahr.com
said: We are very pleased to have acquired a Calibration company of the reputation and quality of Micron. We see this as entirely complimentary to our business of designing, manufacturing and distributing high quality products globally. This acquisition will only enhance our current offering to clients. We further believe that the calibration sector in itself is particularly exciting and set to grow with the continuing advance of regulation and quality control. Micron proudly declares that it is the only Calibration laboratory that you will ever need, and boasts one of the largest scopes of accreditation in the Calibration business. Micron already has a customer list including BP, Airbus, BAE Systems, GKN Aerospace and Rolls-Royce. Since its launch in 1978 as Midland Technologies it has exceeded customer expectations, offering solutions to every calibration requirement. Items that fail calibration can be repaired, refurbished, replaced
and recalibrated in situ and returned quickly, reducing overall downtime to the customer. From its West Midlands laboratory Micron can reach all corners of the UK speedily, should its collection and delivery, or on-site services where required 48-hour Goldtrack or 5-day Silvertrack turnaround guaranteed. Micron recognises that it is its customers peace of mind that is important. To this end it offers a complete management service to cover the critical, the routine and the urgent requirements for calibration. It is due to the hard work of its loyal and well-trained team that Micron can offer the consistently high level of service that its reputation is built on. For more information please email Alan Smith at alansmith @micron-metrology.co.uk or see the websites. www. micron-metrology.co.uk www.rhopoint.com
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For more innovative products see Bowers all-inclusive 2012/13 product catalogue. To order your copy email new@bowers.co.uk
Unit 15, Bordon Trading Estate, Bordon, Hampshire GU35 9HH Telephone: 08708 50 90 50 Fax: 08708 50 90 60 www.bowers.co.uk new@bowers.co.uk
Partners in Precision
can be calculated on the fly against either formulas or standard tolerances. Technicians are given immediate feedback on the status of the calibration. After completion of the calibration, all test point findings are immediately stored and included in a digital certificate. This is stored along with the calibration and can
optionally be printed without prompting. This reduces steps for the technician to perform. The system also supports tracking of repairs to equipment and associated parts, with labour and inventory counts of used parts calculated immediately. www.indysoft.co.uk
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Specific areas covered include: Mechanical Dimensional Electrical Pressure Torque Time Mass......
Contact our sales team for a free no obligation quotation on 0121 784 7498 using extension numbers 201 or 203. General Enquiries Email: sales@micron-metrology.co.uk Web: www.micron-metrology.co.uk
Pressure Gauges Combination Gauges Digital Pressure Indicators Manometers,Oxygen Gauges Pressure Calibrators Pressure Switches Pressure Transducers Sphygmomanometers Dead Weight Testers Autoclaves
Online certification and calibration system management Complete managed calibration system consultancy service Guaranteed turn-around times of five days or less (48 hour Goldtrack Service) Emergency response when required Onsite UKAS calibration service Electrical and mechanical repair service Collection and delivery service Uk agents for Indysoft Gauge InSite International services On-shore/off-shore
MARKETS COVERED: AUTOMOTIVE AEROSPACE PHARMACEUTICAL OIL & GAS MARINE & RAIL
Based on an industry proven technology that combines a laser and a camera to create a triangulated co-ordinate system, the GapGun range can measure not just gap and flush, but also radii, chamfers, weld pro-
files, seals, scratches, and break edge measurements to high levels of accuracy and repeatability with no contact. www.third.com
Long Slip Gauges, Length Bars & Accessories Surface tables, Calibration & re-furbishment Optical Flats and Parallels Quality system consultancy, 1 day or long term
Unit 11 Holman Road, Liskeard Business Park PL14 3UT Tel: 01579 324108 Fax: 01579 347714 Web: www.jkmetrology.com Email: johnkellyselect@hotmail.com
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Precision Measurement Systems from Spectrum Metrology What do you want to measure?
Flatness ... Angle ... Level ... Alignment ... Squareness ... Straightness ... Surface roughness ... Ra / Rz / Rv ...Twist ... Form ... Concentricity ... Waviness ... Diameters ... Lengths ... Radii ... Angles ... Chamfers ... Centres ... Planes ... Cones ... Roundness
Talk to us: With many years metrology experience Spectrum Metrology is not just a distributor: we take the time to understand your application study your drawings measure your components and offer you the best solution to your measurement problems: Email: sales@spectrum-metrology.co.uk Tel: 0116 2766262 www.spectrum-metrology.co.uk
SPX Clyde Union, based in Sheffield, needed extra line boring capacity for the production of a range of centrifugal pump cases, and decided the optimum route was re-engineering the existing equipment. The combined result of the reengineering-CNC retrofit project is a machine that has effectively been given a new lease of life for machining a range of pump designs. Production Control Manager Bob Scrivens enlisted the re-
wanted to maintain standardisation of control technology so its machine operators were confident in its use. The TNC 320's clear overviews of all information and its graphic support during program entry, test run and actual machining, were also big pluses.
Today, the new-look machine is consistently handling workpieces of up to eight tonnes on its 1,800 mm by 1,500 mm table - a cost-effective alternative to buying a new machine, said Bob Scrivens. www.heidenhain.co.uk
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Coal play: Bowers Metrology equipment is being used to aid coal production at a Northumberland based surface mining operation managed by The Banks Group. The issue was wear on steel linings of excavators buckets and the bodies of dump trucks. High costs when heavy plant was out of commission led the company to Bowers' robust TT-300 ultrasonic thickness gauge. Regular checks using the portable TT300 not only prevent failures in use but its large memory capacity and an RS 232 output also means it can create a history and better target early intervention. www.bowers.co.uk Open doors: Man and Machine will be opening the doors of its Oxfordshire training centre on November 7 to offer free Autodesk Certification and exam preparation all day to any delegate who wants to gain a professional CAD qualification. Delegates are allowed to sit as many exams as they want on
the day. Autodesk certification is a reliable validation of your skills and knowledge, and can lead to accelerated professional development, improved productivity and enhanced credibility for you and your employer. Man and Machine will be offering Autodesk Certification for AutoCAD 2013, Autodesk 3ds Max 2013, Autodesk Inventor 2013, Autodesk Maya 2013, Autodesk Revit Architecture 2013 and AutoCAD Civil 2013. Register your place now at: www.manandmachine.co.uk/ training www.bowers.co.uk Faro deal: Faro has signed an OEM and distribution agreement for 3D laser scanners with Trimble, which applies technology to make field and mobile workers in business and government significantly more productive. It will provide Trimble with an OEM differentiated product based on its successful FARO Laser Scanner Focus3D platform. Trimble will offer the OEM prod-
uct throughout its worldwide survey and building construction distribution networks. www.faro.com/uk Faster and faster: Hexagon Metrology has announced further developments to its laser scanner technology for portable measuring arms. The integrated laser scanner for the ROMER Absolute Arm is now significantly faster than previous versions, offering an acquisition speed of up to 50,000 points per second. This enables users to move the scanner over the measurement object faster than before, while achieving the same high data quality even on difficult to scan surfaces like high-gloss carbon-fibre. This means that users can now scan up to 66% more surface area in the same amount of time. Also,
laser scanning can now be carried out wirelessly. www. hexagonmetrology.co.uk Gold offer: PSL DataTrack has launched a DataTrack Gold Medal system offer to mark the 2012 Olympic year. Between now and 31 December 2012, engineering sub-contractors and other companies involved in batch production can purchase a DataTrack Gold Medal system, with a single user licence, for 2012. The special offer is on its DataTrack production management and business administration software. It has modules for DataTrack Estimates & Quotations; Sales Order Processing; Company Letterheads; and Reporting. www.psldatatrack.com
Press Releases Here is a selection of Press Releases received at GTMA offices. If you want to be considered please send your releases by email and in a Word document to: admin@gtma.co.uk with the Subject: Press Release.
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the lead partner in what promises to be a new and exciting field of research, he said. The development of this new process will offer significant advantages in widening the scope for component design, faster production rates and lower energy consumption per component produced. The company is also reported to be looking at applications for the technology outside aerospace, including automotive and energy. www.denroy.com
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Image shows VERICUT Composites Simulation (VCS) of a composite layup of a U tube component on an mTorres AFP machine.
gramming software for AFP machines. Current customer projects to be highlighted include: a large onepiece fuselage barrel on an Electroimpact multi-machine
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Aerospace...
The new VERICUT drilling and fastening product during an airframe assembly operation. A collision detected on an aircraft rib during machining on a Mazak VTC800 Machining Centre. All images courtesy CGTech which is exhibiting at the Aero Engineering and Composites event.
AFP fabrication cell; a U-channel structure onon a 7-axis mTorres AFP machine; and aircraft skin panels and other parts using an AFP head mounted on 6-axis robots from KIKA, FANUC and ABB. CGTech will also show the recently released version 7.2 of it's market leading VERICUT CNC machine simulation and optimization software. VERICUT simulates all types of CNC machining, including aerospace processes such as multi axis milling, drilling and trimming of composite parts, water jet cutting, robotic and mill/turn machining. VERICUT 7.2 has a host of improvements over previous versions including significantly improved performance resulting from 64 Bit processors and multi-threading. VERICUT Drilling and Fastening is a new software application for simulating and programming auto-drilling and fastening machines. These machines are used to assemble large aero-structures and it is essential to avoid programming errors and collisions at such a late stage in the aircraft manufacturing process. The CGTech product allows users to programme drilling and fastener assembly operations in a virtual machine tool environment and provides simulation to check for a variety of potentially disastrous error conditions. Like all VERICUT software the new module interfaces to leading CAD/CAM/PLM systems such as Dassault Systemes CATIA and Siemens NX, and is independent of the assembly machine manufacturer. www.cgtech.com
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Snowboards; Stuart Burns, Technical Director, Rotite Technologies; Anthony Reeves, Lead Engineer, GlaxoSmithKline; and Dan Johns, Process & Technologies Engineer, Bloodhound SSC. This year also saw the introduction of a dedicated jewellery session looking at how additive manufacturing and 3D printing processes are being used in this innovative sector. It gave jewellery designers, manufacturers and silversmiths an opportunity to hear how their peers are already reaping the benefits and enhancing their designs. This year also provided attendees with clear insight into the latest additive manufacturing developments with gold. Within this conference session speakers included Joerg Fischer-Buehner, Legor Group SpA; Mark Bloomfield, Electrobloom; Luke Orford, Grant Macdonald; Silvia Weidenbach, Weidenbach; and Lena Thorsson from Cookson Precious Metals Ltd. TCT Live also offered a wide range of free live educational seminars. Spanning the two days the TCT Technology Tracks included: Inspection, Digitising & Metrology in Product
Development & Additive Manufacturing, with case studies and interactive demonstrations; Additive Technology Introduction Session, presented by industry-guru Graham Tromans who explained how additive manufacturing technologies can advance product development and manufacturing processes; Digital Manufacturing & Materials for Dentistry, showing how more and more laboratories recognise the advantages of incorporating cuttingedge techniques into their process; Software in Product Development & Additive Manufacturing - an in-depth look at some of the leading CAD/CAM/PLM software currently available; and
Technical Briefings in Metals and Non-Metals, aimed at those wanting to source and purchase 3D Printing or AM machinery. TCT this year also saw the introduction of the Personalize Pavilion, a dedicated pavilion to bring the industry to life on the show floor with many products and services for the 3D Printing and personal manufacturing communities for at-home makers and from-home personalizers. Running alongside TCT Live was Mediplas, MM Live UK, MEMS Live and NANO Live these events combined with the PPMA Show and the Sensing Technology Show made up one of the largest gatherings of engineering professionals in the UK in 2012. www.tctshow.com
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TCT Live... TCT Live... TCT Live... TCT Live... TCT Live...
GTMA Exhibitors
TCT Live 3T RPD www.3trpd.co.uk John Burn & Co www.johnburn.co.uk Central Scanning www.central-scanning.co.uk Concept Laser www.concept-laser.de EOS www.eos.info ES Technology www.estechnology.co.uk Europac 3Dimensional www.europac3d.com Faro UK www.faro.com/uk GOM UK www.gom.com Hexagon Metrology www.hexagonmetrology.com Mantech Geometrics www.mantechgeometrics.com Midas Pattern Co www.midas-pattern.co.uk Nikon Metrology www.nikonmetrology.com Physical Digital www.physicaldigital.com
ProtoLabs www.protolabs.co.uk Renishaw www.renishaw.com Steinbichler www.steinbichler.co.uk Trac Measurement www.trac-group.com Werth Metrology www.werth.de Carl Zeiss www.zeiss.co.uk/metrology MM Live, MEMS Live, Nano Live Alicona www.alicona.com Bruderer www.bruderer.co.uk Metrology Direct www.metrology-direct.com Nikon Metrology www.nikonmetrology.com Orlin Technologies www.orlin.co.uk Rofin Baasel www.rofin-baasel.co.uk The L.S.Starrett Co www.starrett.co.uk Vision Engineering www.visioneng.com
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Events 2012
2012 October 17th GTMA 6th Make Measurement Matter Roadshow, CEME, Rainham, Essex October 18th FAST Exhibition, National Motorcycle Museum, Birmingham November 7th8th Aero/Composite Engineering, NEC, Birmingham, Stand 1113 November 21st Aerolink , Farnborough, GTMA Stand November 27th30th Euromold, Frankfurt 2013 January 10th13th Autosports International, NEC, Birmingham April 18th FAST Exhibition, RAF Cosford May 2013 GTMA Manufacturing Event, Yamazaki Mazak, Worcestershire. Date tbc June 4th6th Subcon, NEC, Bimingham June 18th19th PDM, Telford
NEXT ISSUE Our next issue will see special opportunities for promotion for members in Jigs & Fixtures, Mould and Die, and Workholding, Cutting and Ancillary Equipment as we continue the At the Heart of... Manufacturing UK series. Supporting this will be a major feature on Manufacturing and previews on Subcon and PDM where the issue will be distributed. For more information call Colin Swindells on 01243 828358 or email colin.swindells@tiscali.co.uk
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