Multi-axis CNCs ramp up production of electric vehicle parts

Addison Saws, the West Midlands based machine tool supplier, recently installed a total of four Mecal CNC machining centres into Hydro Components (formerly SAPA) to increase production of complex aluminium parts destined for state-of-the-art electric vehicles.


The new machines were part of Hydro Components’ recent investment of £9.6 million in the refurbishment and re-opening of its manufacturing plant based in Bedwas, Wales. This included adding three Mecal Kosmos 4-axis machining centres and one Mecal Geos MDT 5-axis machining centre, said to be the first of its kind in the UK, along with a restructuring of the company’s entire Welsh plant.

Fuelling this investment was an extensive contract for the supply of aluminium body components intended for manufacturers of zero emission vehicles aiming to tackle pollution levels on the streets of the UK.

“At first, Hydro needed to outsource the CNC machining element as issues with its existing machines meant it lacked the functionality to produce the parts themselves,” explains Mike Grogan, Addison regional sales manager.

“Hydro began to use a local subcontracting company operating three Mecal Kosmos machining centres which were ideal for producing the required parts. However, it soon became apparent that bringing the operation back in-house would be more beneficial in terms of turnaround time, overall cost and allowing for greater control over the manufacturing process.”

After the successful installation of the Kosmos machines, Hydro’s production manager at the Bedwas plant was interested in setting up a single step automated production line, eliminating the need for additional saws. After in-depth discussions, Hydro placed an order for the new 5-axis MC 302 Geos MDT 8.6m Mecal CNC machining centre.

Addison Saws then flew key members of the Hydro production team out to Mecal’s factory in Italy to view the machine in action. Along with seeing the factory, the management team were reassured knowing that the machine tool builder’s software could handle the bespoke programmes required for complex parts.

Leading CNC engineer Ian Freeman from Addison Saws has been instrumental in the installation of all the Mecal machinery, which is now working to near-full capacity producing the 70 separate profiles required for one of Hydro’s current contracts.

Hydro’s production manager comments: “Addison have been a great help all round, from selecting the right machinery to assisting in the program writing and ensuring we get the very best out of all our machines. They even supplied an engineer to assist us with machining centres bought elsewhere. We are very pleased with our choice; it has enabled us to tender and win several similar upcoming contracts with major names in the automotive industry.”

Since installation, engineers from Hydro have flown out to Italy to receive one-to-one training from Mecal and this forms part of its strategy to ensure that the machines work to their full potential and the company has capable engineers in place who have in-depth knowledge and a full understanding of how they operate.

In excess of 130 jobs will be created over the next five years at the recently re-opened Bedwas plant and the investment is backed by the Welsh Government, which was keen to invigorate the area with the prospect of new jobs and increased industrial development.

The 4-axis Mecal MC 305 Kosmos machining centre is equipped to automatically machine, drill, mill, slot and prepare both aluminium and steel extrusion bars. Providing high levels of flexibility, it is also well suited to new product development, while its excellent accuracy and repeatability ensure minimal waste.

The machines come in three versions: the TF version with manual clamps and laser pointer, DPM version with automatic clamps positioned by the head and the MMI version with automatic motorised vices.

The machines also feature: An A-axis profile rotation +125° to -125° to work three sides; full CAM-3D software and integration with external software; a centralised eight tool magazine; open ends to allow for machining up to 8,000mm and encoded rotation to work intermediate angles.

The 5-axis Mecal MC 302 Geos-5 MDT machining centre is designed for the high-speed machining of aluminium, steel, brass, copper and PVC materials. It can be used for processing slots, pockets, holes and custom shapes as well as end slotting, tapping, rigid tapping, drilling and flow drilling. The addition of a 400mm sawblade enables the user to cut pieces to length before machining.

It also features compound machining angles using both the A- and C-axis. A-axis 250° rotation for working on three sides and C-axis 440° rotation for working profile ends.

Additional elements include: an HSD liquid cooled 12kW encoded spindle for rigid tapping applications; saw blade up to 400mm; an optional angle drive unit to machine profile sides; pendular loading for seamless production; zero stops at each end to work multiple profiles; and an automatic tool magazine with 18 positions.

The Addison Saws product range includes everything from simple, manually operated sawing machines to highly sophisticated, fully automated sawing lines. This has recently been increased with the addition of heavy duty 3-, 3+1-, 4- and 5-axis long-bed multi-piece machining centres.

Through Addison’s Tube Division, the group also offers an extensive range of tube manipulation technologies. Addison Saws is part of the Addison Group, an organisation that also includes Dynashape, one of the UK’s most experienced saw blade servicing and manufacturing specialists.

Addison Saws www.addisonsaws.co.uk

Hydro Components www.hydroextrusions.com

Company

Addison Saws

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