Coventry-based
Automotive Trim Developments (ATD) has recently acquired three new machining centres, an automated workpiece pallet changer and a large-capacity die-sink machine supplied by
GF Machining Solutions Ltd. ATD, established in 2000, is a UK-based group of companies focused on engineering and manufacturing complete interior trim and electro-mechanical assemblies primarily for the automotive sector.
The new machining centres, comprising two Mikron MILL E 700U simultaneous five-axis machines (pictured above) and a Mikron MILL E1200 three-axis machine (pictured below), as well as a new System 3R Work Partner 1+ compact workpiece pallet change system (pictured above), were delivered and installed at ATD’s new 7,000ft
2 machine shop in Warwick in April 2022, following in the footsteps of a large-capacity AgieCharmilles FORM E 600 die-sink machine which was installed late last year.
The catalyst behind ATD’s investment in advanced machine tools and associated manufacturing technologies centred around a new manufacturing contract with a leading UK-based car manufacturer.
The six-year contract to machine, assemble and supply high-quality centre consoles featuring a rear compartment deployable table, for a new, exclusive range of luxury SUVs accelerated ATD’s investment plans to create an advanced, well-resourced and fully functioning machine shop facility capable of handling the company’s existing and future machining requirements.
Paul Gibson, ATD Warwick operations manager, said: “In a drive to improve quality, control costs and better meet customers’ exacting lead times, we made the decision, at the start of the pandemic, to invest in, and create, a high-quality machine shop that would not only meet all of our future machining requirements - but also strengthen our portfolio of services to customers and make us more efficient and competitive.
“It was always our intention to create an in-house machining resource: the contract for machining the centre console components was the catalyst to get the ball rolling.”
Starting from scratchThe decision to create a new machine shop from scratch was bold but one entirely in keeping with ATD’s mission, vision and ambitions. Mr Gibson reflected: “It was a challenging time. But, with the resources available from the Group, and by working in partnership with a number of preferred suppliers, we got the machine shop up and running in a little under two years.”
In addition to the three new machining centres, the Work Partner 1+ automatic pallet changer and the FORM E 600 die-sink machine, the facility also features two EOS M 290 metal 3-D printers which were also acquired to help fulfil the centre console machining contract. Other machines in the facility include another MILL E 700U with seven pallets, and an older three-axis VCE 1200 vertical machining centre.
Mr Gibson explained: “We have a good relationship with GF Machining Solutions and previous experience of working with the company has always been positive. Although we did look at other options prior to making the most recent investments, it soon became clear to us that no other machine tool manufacturer or supplier could provide the depth and breadth of advanced technologies we needed, nor the technical and applications support we required.”
The components, all machined from aluminium, are characterised by their complexity and intricacy. Geometric tolerances are extremely tight (+/-5µm), repeatabilities are critical and surface finish requirements are equally exacting (Ra 0.2µm). To increase the company’s productivity, the compact and modular Work Partner 1+ system supplied to ATD has 20 pallets and is being used to services both machines.
The Mikron five-axis machines are able to machine complex, high-precision to completion in a single set up. They have a rigid design and build and are equipped with the latest TNC 640 Heidenhain touchscreen control. The machines also feature fully supported, directly driven rotary tilting tables that ensure accuracy and process reliability and 36kW 20,000rev/min StepTec OptiCool motor spindles deliver the high accuracy required — even during long machining runs and extended periods of operation.
To facilitate lights-out, unattended operation, the machines have large 60-position tool changers, efficient swarf management systems, tool and workpiece probes, large coolant tanks and integrated thermal compensation.
MILL E 700U machines are equally adept at performing high-material removal and fine finishing operations — both of which are prerequisites for machining the aluminium centre console parts – where precision and aesthetics go hand in hand.
Mr Gibson explained: “MILL E 700U machines are usually equipped with five or seven pallets. However, from talking over our machining requirements with GF Machining Solutions, it became clear that we could significantly improve our productivity and operational efficiencies by integrating both machines to a high-capacity System 3R automatic pallet changer instead of using the machines’ standard automation configuration.
“The System 3R pallet changer with its vertical pallet stacking configuration is compact, and the 20 pallets available enable us to achieve uninterrupted machining of prototypes, pre-production and production parts, as well as giving us the ability to meet the customer’s stringent delivery schedules.”
“The creation of the cell with the two Mikron machines and the 20-pallet WorkPartner 1+ involved GF Machining Solutions designing, developing and implementing a turnkey solution for us. The skill and expertise of the company’s technical staff has enabled us to benefit from a bespoke, ‘state of the art and future-proofed machining and automation solution.”
The new, next-generation three-axis MILL E 1200 VMC acquired by ATD to machine the centre console components was the first of its kind installed anywhere in the UK. The ergonomically-designed machine is equipped with a temperature-controlled HSK - A63 high-speed 26kW 20,000rev/min spindle, a 60-position ATC, linear guides, a high-efficiency swarf management system, the Heidenhain TNC 620 control, and features a large worktable (1,450 x 600mm), with a 1,200kg maximum table load.
Since being installed the MILL E 1200 has been put through its paces machining multiple parts to high accuracies and mirror surface finishes in a single set-up. Mr Gibson continued: “The MILL E 1200 is a real workhorse and provides us with best-in-class milling flexibility and process efficiency. The large-capacity FORM E 600 EDM die-sink machine was installed at ATD’s machine shop facility in October 2021 and was the company’s first machine to be acquired in relation to the centre console machining contract.
With its large work envelope and integrated six-position electrode/tool changer, the machine is the major component of a fully automated turnkey EDM solution designed by GF Machining Solutions. It is being used to ‘spark’ high-accuracy, small diameter D-shaped holes (H7) in the high-value ‘club table’ components and is the final machining process to be performed on these parts before they are sent for finishing, polishing and assembly.
The turnkey solution involves bespoke fixturing enabling multiple parts to be machined, using small copper electrodes, in a single set up, and a powerful and sophisticated software program that drives the machining process.
Mr Gibson said: “We approached GF Machining Solutions to help us design an optimised automated die-sink machining solution that was accurate, repeatable, easy to understand and implement for machine operators and that would facilitate lights-out, unattended operations.
The delivery of the FORM E 600 (pictured left) with its innovative fixturing exceeded our expectations and represents a first-class, cost-effective solution. With all its technology and processes in place, ATD Warwick is now gearing up for full production of the centre console components.
To ensure continuous production, ATD is also increasing its headcount from three to 11 people and is actively recruiting milling setters/operators and 3-D printing operators for its day shift and new weekend shift. The company expects to be machining 20 complete consoles per week — each console comprises 12 different high-precision machined components.
Mr Gibson concluded: “The new machine shop, with its advanced technologies, will transform ATD’s performance and productivity. The investment in GF Machining Solutions’ machine tools, automation systems and turnkey solutions has made us competitive and better prepared, not only to fulfil the console contract, but also to win new business in the future.”