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Mapal already offers a wide range of innovative machining solutions for manufacturing individual parts and components in electric vehicles. However, the challenge is an ongoing one that Mapal is continuing to meet. High precision for large diameters using ultralight tools One of the core challenges in electrified automotive powertrains is the high-precision machining of the main bore in the stator housing. Presenting a challenge for the tool and machine, all other steps in the production of the stator housing can be carried out on machines with a HSK A63 spindle configuration. However, in most instances the main stator bore requires machining with HSK A100 spindle. This is down to two factors: firstly, the high cutting torque requirements of up to 500Nm; and secondly, the maximum permissible tool weight and tilting moment. Cost-effective manufacturing with short cycle-times calls for a solution whereby complete machining can be carried out on a single machine with small spindle connections. This is because these machines are characterised by their high spindle speeds, lower investment and operating…

If you’re hearing the term ISO 9001 for the first time, the short explanation is it’s a set of procedures dictating all of the processes in an accredited manufacturing business – everything from the design and prototyping to the manufacturing itself, right through to the delivery of goods and invoicing. As Paul Hughes, Managing Director of Integra Systems, explains, “It’s a set of procedures that pretty much govern the way you do business. “I’ll build a quote in our system. If the job gets converted to a sales order then it gets converted to a work order. Once a work order is raised, all your materials can be purchased from it. In effect, it creates a ‘traveller’ that goes around the factory, through the process, tracks your materials then, finally, it gets invoiced out. So that’s ISO 9001’s underlying framework to the business.” Having the official accreditation has not always been an essential component to doing business at Integra. However, the company’s growth…

Transporting a part inside a shop-floor, mounting and clamping it in a machine tool, and machine set-up are major challenges. Workholding massive and large parts is no easy task, and often requires non-standard solutions. Machining large parts involves removing a lot of material that may cause significant deformations due to unrelieved stresses. Another factor, which leads to dimensional problems, is thermal expansion caused by heat generation during cutting: the large sizes make it much more sensitive compared with more standard-sized workpieces. The necessity to remove a significant material stock requires appropriate chip evacuation to prevent the chip re-cutting, which negatively affects the applied cutting tools. The key for overcoming the difficulties lies in technology, based on effective process planning and utilising the most suitable machine tools, optimal workholding, and minimal part relocation. Single set-up machining represents an absolute ideal for machining a…

As experts in thermal spray technology, QSP Engineering specialises in the reclamation, repair and resizing of worn components, with the company servicing clients come from a wide and diverse range of industries including the mining, construction, earth-moving, marine and industrial sectors. QSP’s large workshop in Bethania, Queensland, allows the team to repair small items such as respraying household irons to repair and reclamation of very large parts worn and corroded through excessive and heavy usage – for example, pivot shafts. Over 40 years of successful operations, the company has built a range of services to meet the needs of its clients, resulting in a highly trained team with expertise in spraying techniques. QSP offers high-velocity oxy fuel spraying (HVOF), arc spraying, ceramic and plasma spraying. The latest laser technology has now been added to this mix, with a Laserline system that allows QSP to offer reliable finished workpieces. With a…

Graphene, a material that is just a one atom thick, has exceptional physical properties. The European Commission launched the Graphene Flagship in 2013 to facilitate the transition of graphene and related materials from academic laboratories to applications. With a budget of €1bn for an initial period of 10 years, the Graphene Flagship is one of Europe’s biggest research initiatives, aiming not only to continue developing graphene in academic laboratories, but spearheading efforts for the commercialisation of graphene, preparing for its widespread adoption in industry. Halfway through the 10-year project, the Graphene Flagship has successfully developed more than 25 commercial products, using the impressive conductivity, strength and flexibility of graphene to improve on the properties of previously used materials. However, bringing a new material to market is not without its challenges. ‎Historically, it takes…

The new Manufacturing Modernisation Fund will contribute $50 million in co-funding over three years to support transformative investments in technologies and processes, as part of the government’s pledge to help manufacturing businesses innovate, develop global competitive advantage, and create new jobs. Minister for Industry, Science and Technology Karen Andrews says the fund will also “support businesses to upskill workers to maximise the benefits of technology” and is a “key part of the Government’s economic plan to create 1.25 million new jobs over the next five years”. Available funding The $50 million funding pool will be accessible via two streams: $20 million for grants of between $50,000 and $100,000 for small-scale technology and efficiency improvements $30 million for larger grants between…

A third-generation family company, Redline commenced operations in 1969 when the legendary record-breaking drag racer Eddie Thomas decided to turn his passion for designing and manufacturing automotive speed equipment into a business. He launched what has gone on to become a precision component manufacturing enterprise, and the drive, passion and high-performance commitment continues today through Eddie’s son Ken Thomas, now Redline’ Managing Director, and his son-in-law Ken Stuart, the company’s Director and General Manager. The two Kens lead a team of highly skilled and dedicated personnel. With an eye to precision, Redline purchased its first Okuma machine in the early 1990s. The company has subsequently developed an enduring, strong supplier relationship with the Okuma brand over the intervening period, with those early precision machines still in operation more than 20 years on. “When reviewing the market for our next new machine, Okuma was the standout with their professional proactive approach,” says Stuart. “It is one of the few companies which has had a constant presence in…

As a manufacturer that works primarily with automotive OEMs, as well as F1 engine manufacturers, aerospace, defence, rail and nuclear business sectors, Advanced Engineering prides itself on its quality management systems. As well as ISO 9001 accreditation, the Birmingham-based company can comply with all requirements, from other industry-specific criteria such as the TS: 16949 Automotive standard and the AS: 9100 standard, to meeting varying customer needs and expectations. The company has spent more than over £3m ($5.4m) on new equipment in the last five years; two of the most recent arrivals have been a VARIAXIS i-700 five-axis machining centre and a Quick Turn 250 turning centre, both from Mazak. This now gives the company a total of 19 Mazak machines, which undertake everything from complex prototype work through to automotive production projects. Such activities entail all levels of…

Just like the world-class manufacturers have done, mid-sized Australasian manufacturers want to increase production efficiency, improve quality and traceability, whilst improving the customer experience by being continuously updated. IIoT technology is a key part of Industry 4.0 and large multinational corporations have already adopted it as an essential part of doing business. It’s not good enough to adopt elements of IIoT for the sake of it though, there needs to be a clear perspective to identify the revenue and profit values at stake, the expected time frame to implement it, the technical enablers required, the optimal level of investment in technologies and services, and the capabilities that must be developed to ensure success. According to the report IIoT platforms: The technology stack as value driver in industrial equipment and machinery…

Are you considering implementing manufacturing control software in your business but unsure of the applications? Or have you just heard about control software and want to learn more? Here are the top seven reasons why manufacturers are choosing manufacturing control software: Improved planning processes While the product is being manufactured, the materials used are tracked to allow you to order materials in advance instead of realising too late, creating a smart manufacturing process. Reduced cycle times Through the use of manufacturing control software, manufacturers have greater visibility and control of the order process from step one right through to completion and the final shipment. By having all steps in the process automated, scheduled and with materials in full supply, there is less chance for scenarios to crop up that would delay the manufacturing process, hence reducing the cycle times. Improved product quality Every part that…

MFB was established by Brian and Faye Bilston in April 1970, taking its name from Faye’s initials: Margaret Faye Bilston. While they remain involved in the business, these days they’ve largely handed the reins to their son David Bilston, now MFB’s Managing Director. “They started the business 50 years ago, and the driver behind it was providing precision sheet metal for the electronics industry,” says David. “And that’s still basically how the business operates today. Our core business these days is data enclosures, but we still offer jobbing shop services.” Over the years the company moved from site to site around Melbourne’s eastern suburbs, before settling at its current base in Wantirna in 2002. Today MFB employs 50 people, with a couple of staff running a sales office in Sydney and the remainder in Wantirna. Its main product range is in electronics enclosures, ranging from the cabinets widely utilised in data centres, to more rugged models for outdoor environments. The company’s customer base is varied, encompassing the data electronics, communications…

I would like to begin with a brief overview of AS/NZS 1554 ‘Structural steel welding Part 1: Welding of steels structures’. An excellent standard, AS/NZS 1554.1 states that a welder must be qualified, by welding a coupon in accordance with the relevant acceptance criteria as outlined in the standard. For shutdown work, particularly where welders move from site to site, this can impose a significant cost impost (especially in time delays) due to the need to requalify every time they commence work on a new site. While this is not so much of an issue for workshop-based fabricators, where the shop will have ready access to the welder’s qualification records, it is a major problem for organisations within the resources, power, defence, and oil & gas industries, who will often employ teams of specialist welders to undertake program-specific on-site…

For most people, Industry 4.0 mainly refers to the Internet of Things (IoT) — the fact that every piece of equipment is interconnected, and how they have the ability to ‘talk’ to each other. True as that may be, the other principles that characterise Industry 4.0 are just as definitive – if not more so. The increased connectivity that modern technology brings enables information transparency, which allows the collection and sharing of vast amounts of data. Industry 4.0 is also characterised by decentralised decisions, where cyber-physical systems act as autonomous agents within its dedicated scope, performing tasks without the need for human intervention, and where humans are still required, Industry 4.0 has shifted their role — from operator of machines to problem-solver — through the use of technical assistance systems. What constitutes technical assistance anyway? Designed to aid operators in their role as decision-makers, assistance systems typically offer…