Organised by the UK’s The Manufacturing Technologies Association, MACH 2024, held at the NEC in Birmingham from the 15-19 April attracts over 26,000 visitors and more than 600 exhibitors involved in all aspects of metalworking technology. The show will be of significant interest to stakeholders in the aerospace manufacturing community.
We begin our round-up of exhibitors with Heller (hall 19, stand 330) whose UK factory in Redditch produces selected 4-axis and 5-axis horizontal machining centres (HMCs) for world markets. A particular focus at the show will be Heller's ability to supply turnkey cells for highly efficient machining of tough titanium and nickel superalloys. Consequently, the machine manufacturer will stress the considerable range of different spindles that it manufactures in-house to suit a vast range of applications.
For example, the HMC on the stand will be an HF 3500 second-generation 5-axis model for which it is possible to select a DC (dynamic cutting) universal direct-drive motor spindle, rated at either HSK-A63/16,000rpm/56kW/180Nm or HSK-A100/12,000rpm/45kW/400Nm. There is also a PC (power cutting) spindle rated at HSK-A100/10,000rpm/45kW/360Nm and an HSK-A100/13,000rpm/45kW/228Nm SC (speed cutting) spindle.
Two further options with an HSK-A63 interface are rated at 12,000rpm/45kW/228Nm (PC) and 18,000rpm/45kW/103Nm (SC). All are produced at Heller's headquarters in Nürtingen and feature the company's Zero-Spindle system for rapid interchangeability. The 5-axis machine itself, which is built in Redditch, has a 710 x 750 x 710mm working volume.
Next up is Horn Cutting Tools (hall 6, stand 210). The wholly-owned UK subsidiary will exhibit a broad cross-section of its extensive tooling range. These include boring tools, end mills for stainless steel machining, threading tools and many more.
One range of tools on display will be the Horn Supermini boring, grooving and chamfering system, a variant with a precision-ground rake face designed for producing ultra-fine bores. The ground cutting edge is free from notches when viewed at a magnification of x200 and the tool can be used to machine components having an inside diameter from just 0.3mm. A sharp insert geometry ensures process reliability, even with very small infeed and cutting feedrates. The specially developed coating is suitable for stainless steels, non-ferrous metals and others.
The Supermini Type 105 system insert requires only one toolholder for well over 1,000 insert variants, which applies equally to left-hand and right-hand versions. The patented, droplet-shape cross section has a vibration-damping effect and delivers excellent repeatability during insert exchange and internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal. Horn also offers the tools with face clamping elements that allow the insert to be changed without having to remove the holder from the machine.
Moving on, Fintek (hall 19, stand 16) will showcase its developments in post-processing and surface finishing. Fintek is UK agent for OTEC Präzisionsfinish disc, drag and stream finishing machines and this year, OTEC has expanded its electro-finishing range.
Manufacturers need speed, capacity and precision to meet in-line production needs. With repeatable surface roughness values down to Ra 0.01µm possible, OTEC stream finishing machines meet these objectives. Automation options include increased chain-feed loading and unloading along with full robotised operation.
OTEC SF machines can also be equipped with ‘Pulsfinish’, a technology which produces rapid relative motion between the media and metal workpiece by quickly alternating the direction of the rotating heads. This produces a perfect finish, faster and without compromising workpiece geometry.
Alongside OTEC machines, Fintek will bring the RENA Technologies Hirtisation process. This allows it to offer additive part post-processing as a subcontract service. Hirtisation removes support structures, powder cakes and partially melted grains and penetrates complex geometries and small diameter holes.
Nearby, Yamazaki Mazak (hall 20, stand 330) will have nine machines displayed as part of its ‘Building For Your Future’ offering. One of the highlights will be the HCN-4000 NEO making its UK debut, a high-performance horizontal machining centre with high productivity, accuracy and environmental performance.
Alongside will be a second NEO machine, the VARIAXIS i-800 NEO, a 5-axis machining centre for fully automatic operation over extended periods. With its high rigidity construction and equipped with a 10,000rpm spindle as standard, machine users will be investing in outstanding accuracy and productivity. The VARIAXIS is being exhibited with the Multi-Pallet Pool (MPP), a multiple pallet stocker system offering flexible storage for 6, 12 or 18 pallets, 500mm in size.
The final UK debut will be the new MAZATROL DX which extends the functionality of Mazak’s PC-based SmoothCAM AI software. MAZATROL DX provides customers with valuable new capability to further optimise production with rapid and automatic quotations, automated part programming, virtual machine simulation, and machine process analysis and optimisation.
Our next exhibitor is Starrag (hall 18, stand 320) who will present a host of new technologies at the show. From the Bumotec product range, Starrag will present its latest turn/mill product lines. The new Bumotec 191neo is a complete machining solution that enables manufacturers to produce parts from bars or blanks; and with new generation linear motors, seven axes and three spindles with five simultaneous axes and up to 90 tools. Designed for stable production with minimum operator intervention, the new 191neo incorporates a new MMI touchscreen interface with a Windows-based PC and a host of additional features and automation solutions.
Also new to the Starrag stable is the Heckert H Compact Series, twin pallet horizontal machining centre. This CNC machine delivers the benefits of a horizontal configuration with a compact footprint.
WFL Millturn Technologies UK (hall 20, stand 351) will present a range of high-end technologies at MACH. The new business division set up in collaboration with Kyal Machine Tools will focus on the latest applications from the different industries WFL serves as well as software solutions specifically geared towards process optimisation, safety and efficiency.
The UK has always been a very important market for WFL, especially in the aerospace industry. In terms of productivity benefits, the main advantage from using WFL’s machine tools is a reduction in the number of different machines required to produce a part. This reduction in complexity has many positive effects on the customer’s production environment. For example, less workpiece clamping means less complexity and simpler production planning.
WFL is also focusing on automation for its customers with expert partner Frai Robotic Solutions. Together they support customers at all stages of their automation projects such as initial concept, implementation, commissioning, and maintenance of the automated system. Frai’s gantry robots and robot cells allow for an extensive range of high-quality automation solutions for maximum customer benefit.
In the same hall, Rösler UK (hall 6, 540) will be exhibiting an array of finishing solutions for traditionally produced and additively manufactured parts.
Rösler’s RMBC Tumble Belt Blast Machine is essentially for de-sanding, descaling, de-rusting, deburring and creating homogeneous surface finishes, and is ideal for perfect cleaning of difficult-to-reach surface areas, with long uptime, high process stability, and consistent shot blasting results.
The R220EC Rotary Vibrator, also on display at MACH, has an inbuilt separation system, designed for processing batch parts, and is perfect for all metal finishing applications from deburring to polishing.
Attendees can also witness two AM post-processing technologies: the M1 Basic and the S1 Wet. The M1 Basic promotes superior surface finish of metal or plastic AM parts in a cost-effective and repeatable fashion. The S1 Wet is a versatile wet-blasting solution for cleaning and finishing surfaces on metal and plastic parts and demonstrates the usefulness of shot blasting technologies for AM applications.
XYZ Machine Tools (hall 20, stand 140) will have a total of 19 machines on display, including the premiere of the XYZ CT65 LTY-S Twin/Sub spindle lathe.
The Box Way XYZ CT65 LTY-S Twin/Sub spindle lathe brings the advantages of automated one hit turned and milled components to XYZ’s customers. The machine can turn parts up to 490mm long and bar feed diameters up to 66mm. With twin spindles, live tooling and Y and C axis, this machine can turn and mill complex parts at both ends in one operation, dropping the finished part into its part catcher for hours of unattended machining.
For heavy duty machining applications, the XYZ 800 HD includes box slideways and massive ribbed castings for maximum rigidity. Matched with the Siemens 828D control with ShopMill and options for 4th axis rotary tables, this machine has the power and capability to machine the toughest materials. The stand will also feature the ever-popular RMX Bed Mills, KMX Turret Mills and RLX Lathes.
Lastly, NCMT (hall 19, stand 130) is celebrating its 60th anniversary this year. It is the sole agent in the UK and Ireland for Japanese-built Makino and Okuma, CNC machine tools.
In 2005, Makino-NCMT Grinding Division was established to develop and sell throughout Europe Makino machining platforms for creep-feed VIPER grinding of nickel alloys and since 2015, NCMT has also been the Europe-wide agent for photo-activated adhesive workholding systems manufactured by Blue Photon. At the beginning of 2024 it signed an exclusive distribution agreement in the UK and Ireland with Tritone Technologies, a global leader in additive manufacturing.
The Rigid, thermally-stable construction of the Okuma Genos M560-V-e vertical machining centre (VMC) protects it from thermal deformation, resulting in high machining performance for an entry-level machine. The 3-axis machine is able to process a variety of materials from titanium to aluminium without sacrificing dimensional accuracy, finish quality or productivity. The machine will be equipped with a Cellro X20 robotic system for component load/unload and storage.
In a space on the shopfloor of less than 3.3m², the N2-5XA horizontal machining centre from Makino is capable of very high-speed machining of components up to 300mm diameter by 270mm high and weighing a maximum of 30kg, including fixture. The machine is ideal for fully interpolative, 5-axis machining of complex components made from difficult-to-cut materials like stainless steel, cobalt-chrome and zirconium, as well as titanium- and nickel-based alloys. Typical applications include impellers and compressor blades for the aerospace industry.
