Third machining cell purchased to fulfil contract

Posted on 10 Feb 2019 and read 693 times
Third machining cell purchased to fulfil contractAt the end of 2017, when Tamworth-based Alcon Components was awarded a contract to supply the lightweight monobloc brake calipers for a new hybrid electric hyper-car, the sub-contractor asked Gosport-based Kingsbury (www.kingsburyuk.com) to supply a second automated turn-key machining cell to produce the aluminium components.

Comprising a German-built Hermle C 32 U five-axis machining centre fed with pallets from an Erowa Robot Easy 250 automated storage and handling system, the cell was delivered in mid-2018 and started pro-ducing the calipers immediately (the job had already been proved out on an almost identical cell installed in 2016).

The hyper-car has one brake caliper per wheel, and a set of four requires more than 24hr of machining from solid aluminium billets. The production route comprises four stages: two on the Hermle C 32 U and two on another vertical machining centre.

Fully interpolative five-axis machining of free-form surfaces accounts for less than 10% of the cycles on the Hermle machine, with 4+1 and 3+2 strategies used wherever possible to maximise production efficiency.

A limited number of these road-going hyper-cars will be produced, and a few ‘track only’ versions are also planned.

Alcon (www.alcon.co.uk) is responsible for the brake system, pedal box and actuation, as well as a number of high-precision chassis components.

When the contract has been completed, Alcon will split its on-going production of calipers for high-performance road cars, racing cars and defence vehicles between its two Hermle-Erowa C 32 U cells.

A smaller C 20 Umachine on the shopfloor will then be reserved for producing prototypes.

Be seen in all the right places!

EMO 2019 TCT Show 2019 TOOLEX 2019 Northern Manufacturing 2019 Advanced Engineering 2019 Metalex 2019 Machine Tool Indonesia 2019 WIN Eurasia 2020 Shenzhen International Machinery Manufacturing MACH 2020