MACH 2020 is the UK’s largest manufacturing and engineering exhibition. Aerospace Manufacturing looks at what visitors can expect to see at this year’s show and features some of the exhibitors involved in aerospace manufacturing.
Scheduled this year to run from April 20-24th at the NEC Birmingham, MACH 2020 is the biennial event that brings together the latest developments and best innovations found in the engineering industry.
It also provides manufacturers of all sizes and sectors the chance to network with key clients and prospects as well as gain insight into their needs and future vision for supply chain manufacturing. Established more than 100 years ago by the Manufacturing Technologies Association (MTA). It attracts in the region of 600 exhibitors and more than 25,000 visitors.
We begin with MSC (hall 6, stand 310), a leading national supplier of metalworking and MRO products and services who will include a life-size deconstructed aircraft engine featuring components - produced by MSC customer, Bromford Industries - on its stand.
The MSC team will be on hand to discuss how its range of products, services and technical support can support manufacturers and deliver greater profitability by driving efficiencies and optimising production processes. Visitors are also invited to take technical drawings along to the stand so that their specific challenges can be discussed with MSC’s engineering experts. Some working examples of MSC’s popular range of industrial vending machines, which deliver visibility, flexibility and control and improve productivity and profitability, will also be on display.
Moving on, the Okuma Spaceturn LB3000 EX II turn-milling centre will make its first appearance in the UK equipped with the Japanese manufacturer's Armroid robotic arm, the first in the world to be integrated inside a CNC machine tool. All Okuma machines are sold and serviced exclusively in the UK and Ireland by NCMT (hall 19, stand 120).
Three different end-of-arm effector options are available for the robot, capable of performing different tasks. One is for blasting the cutting zone with air to improve chip management. Another provides additional support during the cutting process to prevent chatter. In combination with a workpiece stacker, the third effector automatically loads and unloads workpieces weighing up to 5kg. All three are stored within the machine and are changed automatically by the robot. A longer and more powerful robotic arm, Armroid Type 2, will be integrated into an Okuma Multus B250II multi-tasking lathe for high mix, small batch billet work. It is capable of handling workpieces up to 10kg and possesses a fourth end effector with a 3-jaw workpiece hand.
There will be a second Multus machine on show, a U4000 2SW with an opposed spindle. It will be set up to demonstrate the ease, efficiency and cost-effectiveness of power skiving for the production of external and internal gears and splines to world-leading accuracy on a generic 5-axis multi-tasking platform. The final turning machine on the stand will be a Genos L2000 with a gantry-type workpiece load/unload system. Production of a flange-type component will be demonstrated.
The MB-5000H Series 2 twin pallet, high speed, horizontal-spindle machining centre from Okuma will also make its first UK appearance at MACH. The thermally stable machine offers greater rigidity, higher acceleration, shorter tool change and table indexing times and higher power compared with the previous Series 1 model. Powerful cutting capabilities and high-speed automation reduce cycle times and increase productivity by up to 25%, while the 20% smaller footprint maximises utilisation of valuable shopfloor space.
The Genos M460V-5AX vertical machining centre with a working volume of 762mm x 460mm x 460mm will be in evidence again. It was the first 5-axis machine in Okuma's popular Genos entry-level range, but has since been joined by the larger M560V-5AX with 1,050mm x 560mm x 460mm travels. Both machines are designed to manufacture high precision parts at impressive metal removal rates in a compact footprint.
The theme of NCMT's Okuma stand at MACH will feature Okuma Smart Factory. It will exemplify how Industry 4.0 applications can improve manufacturing processes by linking every machine tool throughout an entire manufacturing environment to Connect Plan. This solution allows complete visualisation of the factory and provides analytics for improved machine tool utilisation.
Close by, MACH 2020 will mark the UK launch of the D200Z 5-axis, vertical-spindle machining centre from Makino, which is also represented exclusively in the UK and Ireland by NCMT (hall 19, stand 130).
The 30,000rpm spindle and integral, direct-drive table provides quick, precise, full 5-axis machining. This capability combines with high-speed SGI.5 motion control software in the Makino Professional 6 CNC to maintain the tightest tolerances and quality requirements and ensure accurate blending of 3D surfaces, even during simultaneous 5-axis motion. All of these attributes are essential in the manufacture of modern dies, moulds and components of intricate geometry. Designed to maximise working volume and load capacity, the compact D200Z accommodates workpiece sizes up to 300mm in diameter, 210mm tall and weighing up to 75kg. The X, Y, Z axis travels of 350mm, 300mm and 250mm respectively, feature rapid traverse and cutting feed rates of 60m/min. The machine utilises a lightweight B-axis structure with 0 to +180° of tilt at 100rpm. Both the B-axis and 150rpm, 360° C-axis table feature direct-drive motors for accurate, high-speed operation.
Two other Makino vertical machining centres will feature on the NCMT stand - the 3-axis F5, intended for mould and die work and the 5-axis DA300, which will be demonstrated producing an impeller.
Makino will showcase its Industry 4.0 package of software tools, MPmax, for real-time process monitoring and data management. With the ability to connect a multiple-machine network to a centralised computer, it allows manufacturers to retrieve, store and analyse high volumes of data in real time, enabling detection of and reaction to bottlenecks on the fly, whether it relates to underperformance or process errors.
Also new from Makino will be a wire-cut electric discharge machining (EDM) centre, the U6 H.E.A.T. EXTREME, which uses the largest diameter wire - 0.4mm - of any machine on the market. The wire is coated and distinct from the 0.25mm uncoated brass wire that is commonly used in industry. The demonstration on the NCMT stand will be roughing the fir-tree root form of a turbine blade, assisted by dual pumps delivering high flushing pressure and volume.
Two further Makino EDM machines will be on show. A second wire-cut machine, the U3i with fourth axis, and an EDAF3 die sinking EDM machine equipped with an Erowa Compact 80 magazine for storing and automatically loading and unloading electrodes and components. It will be shown machining root form pockets and the seal slot on a turbine blade.
Completing the exhibits on the stand will be a photo-activated adhesive system from the US, Blue Photon, for which NCMT is sole European agent. The method is ideal for securing awkwardly shaped parts to allow maximum access to tools for tight-tolerance machining or inspection.
The process involves applying an adhesive that is cured by ultraviolet light via an LED spot curing system. After machining is complete, the adhesive contact points can be sheared to free the workpiece by rotating the gripper pins in the fixture plate with a spanner. The residual adhesive can subsequently be removed by application of hot water.
Blue Photon is ideal for clamping a turbine blade to enable the fir-tree and wedge face on the root as well as the shroud end features to be machined in one hit without tolerance build-up. Traditionally, due to clamp interference, multiple operations are required. A novel turbine blade fixture incorporating four gripper inserts has been designed by NCMT that, once adhesive has been applied and cured, holds a blade securely by one side of the aerofoil.
Roemheld UK (hall 7, stand 430) will use MACH to announce a significant diversification to its handling product range. Alongside workpiece manipulators, the company will launch a new suite of cells designed to automate machine tool tending and add extra processes beyond just workpiece handling and storage.
The ProModul concept from Hilma is centred on a core 'R' module, enclosed all-round for safety and equipped with a Fanuc 6-axis robot and two workpiece drawers. It provides a base level of automation for unattended production on CNC lathes, machining centres or other machine tools such as spark eroders.
From the group's Stark division and on show for the first time in the UK will be a robot gripper with zero-point clamping for automated pallet exchange on machine tables without their own media supply. The services needed for clamping and releasing the workpiece, whether hydraulic, pneumatic or electrical, are all transferred to the clamping plate via a multiple coupling integrated into the robot's pallet gripper.
On display for the first time will be Roemheld's pneumatically actuated swing clamps incorporating a mechanical locking action, whereby the full holding force - between 200 and 600N - is maintained in the case of air pressure reduction or loss, ensuring operator safety and avoiding the production of scrap. Operating pressure is between two and six bar.
Two vices designed for workholding on 5-axis machining centres will be exhibited. The Hilma MC-P is able to grip on just 3mm of material, reducing raw material costs, and offers high stability and precision combined with excellent accessibility and comprehensive chip protection. The compact design enables collision-free tool paths and the use of short, standard tools for multi-axis machining.
Another workholding system appearing for the first time at a MACH show will be the division's range of three MC-P Z Balance vices, which have a floating clamping point to avoid stressing or deforming the component being secured.
Meanwhile, 4CM (hall 19, stand 900) will offer exhibitors and visitors looking to grow their businesses a free marketing health check. Industrial manufacturing and engineering businesses who would like to understand what they could change in their marketing efforts to have the biggest impact are invited to visit the 4CM stand to speak to an industrial marketing specialist.
In the same hall, Fintek (hall 19, stand 26) UK agents for OTEC Präzisionsfinish, will be highlighting the advances in mass surface finishing technology, including Industry 4.0 readiness and high-performance stream finishing.
Many advances are being made in high energy stream finishing. Particularly, OTEC’s ‘Pulsfinish’ technology that produces rapid relative motion between the process media and workpiece by quickly changing the direction of rotation of the work holding heads in a programmable and controllable way. High speed acceleration and deceleration increases the finishing forces on the workpiece making it possible to deburr effectively, hone edges and evenly smooth surfaces from Rpk 0.2µm to 0.1µm, in under a minute.
SF machines with new step control are already proving very effective superfinishing systems for aerospace turbine blade manufacturers. This enables the blade angle to be changed during processing to target specific surfaces for precise material removal without affecting the integrity of the blade profile – especially leading and trailing edges.
Further on, Sodick’s (hall 20, stand 310) new 5-axis K4HL small hole drilling machine has been developed specifically to meet the needs of the aerospace industry, such as the high-speed drilling of the thousands of small, high-precision diffuser holes in exotic materials for jet engine turbines.
Making its world debut at MACH, the company is confident that the accuracy and repeatability achieved by the K4HL, together with its use of de-ionised water for dielectric flushing will make it a game-changer in this sector. The K4HL machine is built to the same design as Sodick’s proven and successful AG40L and AG60L die-sinkers and, to ensure the highest level of accuracy, incorporates Sodick linear motor drives on the X, Y and Z axes.
The large granite work table, 750 x 650mm (WxD), can accommodate a workpiece of up to 740 x 640 x 500mm (WxDxH) and a maximum weight of 500kg, with a distance from table-top to the lower guide of between 255–655mm. Electrode diameters are between 0.25–3.00mm with a maximum electrode length of 500mm and the K4HL has a maximum spindle speed of 1,000rpm.
In addition, the K4HL comes as standard with through-hole detection and an automatic electrode feeder which automatically collects worn electrodes and replaces them with new ones, enabling continuous cutting with several electrodes - ideal for a vane and blade production environment. The system also incorporates Sodick’s fully optimised servo control which can improve cutting speeds by up to 200%. The K4HL shown at MACH is a prototype machine which will return to Japan after the show. Delivery of the new machines to UK and European customers is expected from Q4 2020.
In addition to the K4HL, examples of the latest Sodick technology across a range of machining and production processes will be at the show, not only wire and sink EDM, but also high-speed milling as well as horizontal injection moulding on Sodick’s largest-ever stand at MACH.
Component cleaning specialist, Turbex (hall 17, stand 310) will announce optional functionality available in two of its industrial washing machine models, Java and Palma, that increases the efficiency of washing components, improves their cleanliness and widens the range of applications that can be undertaken. Called vector kinematics, the patented feature is in addition to process-specific, targeted cleaning, announced at the last MACH show, which is tailored to large-scale cleaning of families of similar parts.
Debuting at MACH will be a heavy-duty Turbex ACV-1.7-2 aqueous cleaning machine from the company's range of front-loading, spray washing and rinsing machines. The Turbex ProLine range of cleaning lines, intended for applications where a very high level of cleanliness is needed, will be represented on the stand by an automated 550 system with three wet stages and a dryer, plus load and unload stations. There are four variants in the modular, fine and ultra-fine cleaning line range - Easy, Auto, Semi and Auto+.
The latest small-format WARDJet waterjet cutting machine will be demonstrated by AXYZ Automation Group (hall 6, stand 630) at MACH. Part of the A-Series of machines, the A-0612 shares the same industrial design features and performance capabilities of the larger-format series of machines, but in a more compact size. It has been developed to accommodate the requirements of engineering shops and machining centres where workspace is at a premium and the need for more cost-effective production equipment are major considerations.
Open Mind (hall 17, stand 440) will provide manufacturers with an opportunity to witness the steps that hyperMILL has taken with its latest release, Version 2020.1. The latest release introduces new features that include significant enhancements to everything from slot-rib probing, 3D optimised roughing, 3D profile finishing, 3D and 5-axis corner rest machining, 5-axis blade tangent milling, additive manufacturing and automatic contour feature splitting.
In addition, Open Mind has incorporated further improvements to the Settings Wizard, Toolpath Display, 5-axis tube finishing and 5-axis contouring functions with more feature enhancements also incorporated into the hyperCAD-S CAD platform.
The major new features in the latest hyperMILL 2020.1 release arrive from the NC code-based hyperMILL Virtual Machining simulation solution, the Digital Twin concept and the hyperMILL Automation Center.
GF Machining Solutions (hall 20, stand 100) will be showcasing a range of its advanced technology solutions on its stand at MACH. The company will be exhibiting six machines on the stand, with some of them making their MACH debuts.
The machines comprise an AgieCharmilles CUT P 550 Pro wire EDM machine, a Mikron MILL P 500UD and a MILL E 700U with an integrated pallet changer, an AgieCharmilles FORM P 350 EDM die-sink machine integrated with a System 3R WorkPartner 1+ automation system, the new AgieCharmilles CUT AM 500 and the new DMP Flex 350, a robust and flexible metal 3D printing machine.
Two major themes running across GF Machining Solutions’ stand and the technology being showcased are automation - utilising the company’s WorkShopManager and CellManager technologies - and rConnect, the company’s Live Remote Assistance and Machine Monitoring platform.
In addition to the six ‘physical’ machines on the stand, GF Machining Solutions’ product, technical and customer service staff will be available throughout the show to talk to visitors about the company’s pedigree and prowess in delivering advanced manufacturing solutions to customers.
Metrology and inspection specialists, Optimax (hall 19, stand 631), will showcase what it claims is the most accurate purely optical micro-coordinate measuring machine in its class - the Bruker Alicona µCMM at MACH. The µCMM revolutionises the production process, overcoming the inefficiencies of traditional methods by enabling the complete automatic measurement of position, dimension, form and roughness in one device. With its newly-patented ‘Vertical Focus Probing Technology,’ the µCMM can measure vertical walls with a slope of +90°. This device can measure tight tolerance features, even on very smooth surfaces, into the nanometer range.
An automated robust and intuitive instrument, with a 310mm measurement capacity, the µCMM is engineered for permanent use in the production process. Measurement times are significantly reduced with measurement of patch 3D data clouds on selected areas and a drastic increase in travel speed on the X, Y, Z axis. Its intuitive and ergonomic design facilitates multi-user use without specialist training.
By extending from a 3- to 5-axis system, the µCMM can measure flank angle, lead angle, thread pitch and undercutting on components. The device accurately measures all common industrial materials and composites with drastically different reflection properties. Increasingly smooth and reflective precision parts can also be measured with its powerful SmartFlash 2.0 technology.
Disruption is sometimes the only way forward says CGTech (hall 17, stand 330). ‘If you always do what you’ve always done, you’ll always get what you’ve always got’, is a truism that CGTech, developer of VERICUT CNC simulation, verification and optimisation software has been stating to manufacturers in many industry sectors since 1988.
Visitors to the stand can find out how the software can improve (disrupt) their business. With VERICUT, CGTech offers a wide range of products and solutions that ensure CNC machine tools run collision-free and manufacturing processes operate more efficiently with increased profit levels. Machine shops can take back control and get ahead with VERICUT.
Demonstrations of the latest features in version 9.0 of VERICUT CNC machine simulation and optimisation software will be conducted on the stand. VERICUT software is the industry standard for simulating CNC machining in order to detect errors, potential collisions, or areas of inefficiency. It operates independently; but can also be integrated with leading CAM systems.
‘Restart’ and ‘Stop At’ capabilities quickly verify changes made to an NC program, and have more control over the simulation. Initiate Restart action on any line in the NC Program window and the simulation quickly processes up to the restart line, then the display updates to show the result. A new ‘Stop At’ Line Number/Count option enables programmers dealing with looping and branching logic to stop at a specific occurrence number of processing a line in the NC program.
CGTech will also demonstrate VERICUT’s Force optimisation module at MACH. VERICUT + Force provides an integrated simulation-optimisation solution that can significantly reduce machining times, improving cutting tool and machine life. New and legacy NC programs can be optimised with Force to run as efficiently and safely as possible. Force is available for milling, turning, and mill-turn machines.
Elsewhere, Leader Chuck International (hall 18, stand 18) will provide static and dynamic demonstrations of a number of new and recently launched products from its international partners at the show, including: the UK launch of Orange Vice Delta IV compact vices and zero-point subplates; Balance Systems’ range of solutions of grinding wheel balancing, in-line dynamic gauging, touch detection and spindle monitoring with the B-Safe machine tool spindle monitoring system; Autogrip’s new Auto Jaw Exchange chuck (AJC); Hainbuch’s is the Maxxos T211, a mandrel featuring a new hexagonal pyramid shape instead of a round taper; MicroCentric’s recently launched CB-NX series collet chuck featuring a low-profile dead length design with a reduced diameter nose for maximum tool clearance; Walmag Alustar’s permanent chuck, used during turning and grinding of ring-shaped workpieces; Maprox’s range of clamping equipment for CMMs; and a range of efficiency enhancing solutions will also be demonstrated by Leader’s trusted partners, including AMCC, Hewa, Homge, Jato, Lexair and Llambrich.
RK International Machine Tools (hall 20, stand 265) has strengthened its partnership with Italy-based MCM (Machining Center Manufacturing) and will be highlighting its range of high-specification, high-accuracy 4- and 5-axis machining centres at MACH. MCM’s specialisation in the development of flexible machining cells, with a strong focus on the aerospace sector has seen it supply many of the world’s aircraft and aero-engine manufacturers with innovative machining solutions.
MCM machines range from the 800mm of the Clock series, up to 3,000mm for the Tank and Tank G series and over 6,000mm for the Jet Five family of machines, with the vast majority of its production being integrated into flexible manufacturing cells, all of which is managed in-house by MCM from machine construction, control systems through to final installation and integration.
Finally, the Ceratizit Group (hall 18, stand 210) brands Ceratizit, Komet, Klenk and WNT, will be represented at MACH under the Team Cutting Tools banner, with the opportunity taken to introduce a wide selection of new and innovative cutting tool developments to further enhance productivity and reduce costs for customers.
The focus at MACH will be on improved productivity with major announcements such as the completely new range of Silverline solid carbide milling cutters being unveiled at the show, as well as new turning grades and toolholding systems that will help drive down manufacturing costs. In addition, visitors to the Ceratizit stand will also see first-hand the revolution that is High Dynamic Turning with Ceratizit’s FreeTurn tooling, which combine to flip turning techniques by maximising the capabilities of modern turning centre technology.
MACH-2020
