At Presto  we understand how  high end audio design  combines technology and aesthetics to achieve the desired end product. Presto  have the expertise and specialism  required to produce consistent parts that are  required for the high end audio market.  We take responsibility for all aspects of your machining  from submission of the drawing to on time delivery of your components with a pristine finish.

We offer a range of finishes and the application of the product usually determines the choice of finish.  For visible Precision Machined Audio Components  where appearance is key, aluminium lends itself to stylish finishes such as anodising and wet paint. At Presto we take the dimensional accuracy and visible finish of our parts very seriously. When it comes to visible parts they are 100% checked prior to and after the finishing process.

We pride ourselves on the relationships that we’ve built with our customers. They tell us that our attention to detail is ‘second to none’. Whatever your requirements  we work with you to find the best solution for your hight end audio product.

Could Presto’s expertise help you?
If you’d like to find out more about Presto Engineering contact us to discuss  your  precision engineering requirements.
01865 883508        sales@prestoeng.co.uk

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We look forward to welcoming you to our new premises when we are back to the new “normal”, but in the meantime we remain open for busniess and  please don’t hesitate to contact us to discuss your machining requirements.

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Precision engineers in the South East of England covering Oxfordshire, Buckinghamshire, Berkshire, Hampshire, Surrey, Kent, West Sussex, East Sussex & Isle of Wight.

Presto Engineering have many customers in Oxfordshire, the surrounding areas, nationally and internationally. We are always keen to talk to businesses who are looking for a new supplier. Presto are able to give you a single point of contact for procurement of your finished parts.

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The post CNC Machined Aluminium Parts in the Cotswolds & Thames Valley first appeared on Presto Engineering.

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Aluminium History

Aluminium is the most widespread metal on Earth, making up more than 8% of the Earth’s core mass. It’s also the third most common chemical element on our planet after oxygen and silicon. The Persians made extra strong pots from clay containing aluminium oxide, dating back to 5300BC. The ancient Greeks and Romans used alum in medicine as an astringent and in dyeing processes. But  Aluminium does not occur naturally in its purest form. It wasn’t until the 19^th Century  with the developments in chemistry and the advent of electricity that aluminium was discovered. It is generally found  in minerals and compounds such as feldspar, beryl, cryolite, and turquoise.The primary raw material for aluminium production is  Bauxite. Bauxite is generally  found in topsoil located in various tropical and subtropical regions, reserves are most abudant  in Africa, Oceania and South America.

In the first stage of aluminium production bauxite is processed into alumina, or aluminium oxide. Alumina looks like white powder and it is then processed into aluminium at aluminium smelters using electrolytic reduction. Aluminium ingots are produced in various shapes and sizes depending on their end use. They may be rolled into plate, sheet, foil, bars or rods.

Aluminium Smelting

Benefits

Lightweight

A known lightweight metal, it has a specific weight of approximately 2.71 g/cm3. It’s about a third of the weight of steel, which makes it easier and cheaper to transport than most other metals. The strength of aluminium can be adapted using varying alloying elements to provide better benefits including higher strength or easier formability.

Corosion Resistance

Aluminium is a corrosion resistant metal that naturally generates a protective coating. The coating formed is extremely thin and is generated when aluminium comes into contact with an oxidising environment. This protective aluminium oxide layer helps protect the surface of the metal from corrosion. Additionally, getting surface treatment such as painting or anodising can further improve the overall corrosion resistance of the metal.

Electrical and Thermal Conductivity

It is an excellent conductor of heat and electricity. Although aluminium is not as conductive as copper  but it is approximately a third of the weight. An aluminium wire with half the weight of a copper wire would have the same amount of electrical resistance. As a result, it is the chosen material for power transmission lines. It is also an excellent conductor of heat. It is used as heatsinks in  applications such as LED lights, electrical products, computer motherboards, etc.

Reflectivity 

Another benefit of Aluminium is that it serves as a good reflector. Aluminium is used in rescue blankets and light fittings because of its ability to reflect both light and heat.

Odourless and Impermeable

Even with 0.007 mm thickness of aluminium foil, it is still impermeable and doesn’t have a substance taste or smell. This is non-toxic and often used for packaging of the sensitive products including pharmaceuticals and food.

Recyclability

Aluminium is a 100% recyclable and during the recycling process, it retains all of its original properties. It is more cost-effective to use recycled metal than prime metal out of the ground.

For more information about Presto Engineering please visit our website here and if you would like a quote or to discuss a project with us please call us on 01865 883508 or e-mail: sales@prestoeng.co.uk.

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The DNM 6700  is a large-capacity machine equipped with a generous-sized work table (1500mm x 670mm). With impressive axis travels (X-axis:1300mm x Y-axis: 670mm x Z-axis: 625mm).

Doosan DMN6700

The installation of the Nikken 4 & 5 Axis Rotary Table means that we can  provide our customers with a complete solution to their CNC Milling requirements, including the most complex of aluminium machined parts. The Rotary Table enables parts to be manufactured in “one hit”. This improves accuracy and eliminates the need for multiple set ups. The table and travel capacity  of the DNM6700, gives greater flexibility in complexity and size of components that Presto manufacture.

Nikken 4 & 5 Axis Rotary Table

At Presto Engineering by continually investing in machinery it  allows us to offer fast production, reduced costs and always at the forefront of our philosophy, the highest standards of finish.

Could Presto’s expertise help you?

If you’d like to find out more about Presto Engineering, contact us to discuss  your  precision engineering requirements.

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Extrusion is defined as the process of shaping material. In this case aluminium, by forcing it to flow through a shaped opening in a die.  Extruded material emerges as an elongated piece with the same profile as the die opening.  The extrusion process makes the most of aluminium’s durability, flexibility and light weight.  Its malleability allows it to be easily machined and cast. Aluminium is one third the density and stiffness of steel so the resulting products offer strength and stability.

Why use Aluminium Extrusion?

The aluminium extrusion process provides almost unlimited opportunities to the product designer with the added benefit of low tooling costs and short lead times.  Components can be designed to incorporate extra features that provide fixings, channels and interlocking systems that preclude the need for additional parts.  These features can even be incorporated so that they enhance the structural strength of the assembly.

The use of  extrusions in combination with novel fabrication techniques can be a low cost tooling solution.  The prototype costs can be reduced during design and the manufacturing technology is easily transferred into full production.

It is not just in new product design where the benefits of aluminium extrusions can be appreciated.    In existing products the substitution of other materials and processes with aluminium extrusions can result in cost saving through fewer components, reduced finishing, simplified assembly and improved supply chain logistics.

The Extrusion Process

There are two main methods of extrusion – direct and indirect.  Direct extrusion is the most frequently used  whereby the die head is held stationary and the aluminium billet is forced through the die using a moving ram.  In indirect extrusion, the aluminium billet is held stationary and the ram moves the die to exert pressure in the stationary billet.

Direct extrusion is commonly used in the manufacture of solid rods, bars, and hollow tubes. The design of the die can be modified to produce a wide variety of solid and hollow profiles.

The material for making extrusions is the aluminium log.  These are cast in lengths of up to 7 metres and available in a wide range of alloys and diameters.  After casting they are further heat treated (homogenised) before being supplied to the customer.

The first operation is to cut the long extrusion log into suitable lengths for extrusion based on press capacity and the final extruded length which is typically 400mm to 1000mm.  The cut log (or billet) is fed into the billet heater where it is heated to 400-500^oC.  The exact temperature will depend on the alloy shape, complexity and other process parameters.

Extrusion involves pressing a preheated  ingot (450-500^oC) under high pressure (1600-6500 tons depending on the size of the press) through a die the opening of which corresponds to the cross-section of the extrusion.  In the traditional direct method of extrusion the die is stationary.  The length may be as long as 50 metres and may consist of one strand or multiple strands of the same section.

The extrusion is cut and moved along the cooling table.  When cooled it is  moved to the stretcher which straightens the extrusion and performs ‘work hardening’ or molecular re-alignment which gives it increased hardness and improved strength.

Some of the benefits of using Aluminium Extrusion

In general and extrusions in particular, offer a number of benefits relative to alternative materials and processes including:-

Lightweight 

Aluminium is about 1/3 the weight of iron, steel, copper or brass. Making  extrusions easier to handle, less expensive to ship, and an attractive material for use in applications where weight reduction is a priority such as transportation and other applications involving moving parts.

Strong

Aluminium extrusions can be made as strong as needed. Due to the nature of the extrusion process, the strength can be concentrated where it is rquired by including varying wall thicknesses and internal reinforcement in the profile design.  Cold-weather applications are particularly well served by extrusions, as it becomes stronger as temperatures fall.

High in strength-to-weight ratio

Aluminium extrusions unique combination of high strength and low weight makes them ideal for applications like aerospace and bridges where load carrying is a key performance.

Resilient

Aluminium combines strength with flexibility, and can flex under loads or spring back from the shock of impact, leading to the use of extruded components in automotive crash management systems.

Corrosion resistant

Aluminium extrusions offer excellent corrosion resistance.  They do not rust, and the aluminium surface is protected by its own naturally occurring oxide file, a protection that can be enhanced by anodizing or other finishing processes.

Quick-to-market

Tooling is relatively inexpensive with generally short lead times, facilitating swift prototype development, testing, and product launch.

Easy to fabricate & assemble

Effective design can greatly simplify subsequent fabrication and assembly, and there are a wide variety of fabrication processes that are routinely employed in the production of extrusion-based components and assemblies.

Sustainable

Aluminium can be recycled with no degradation in properties. Aluminium extrusions are often produced with high recycled content without compromise to aesthetics or functionality.

Contact

If you would like further information on Aluminium Extrusion or any other topic relating to CNC milling of aluminium machined components please get in touch at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like a quote or to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

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Diagrammatic representation of 5 Axis Technology

Advantages of using 5 axis technology versus conventional 3 axis machining include:-

Minimal set ups required

5 axis technology eliminates the multiple set ups required to re-position the workpiece at complex angles when using 3 axis machining.  This results in increased productivity and reduces the time and cost of preparing fixtures to hold the workpiece in place.  In addition, with multiple set ups in 3 axis machining there is always the possibility of incorrect alignment each time the part is moved.  Five axis machining requires minimal intervention and results in higher part accuracy.

Reduced requirement for fixtures and tools

5 axis machining minimises the requirement for fixtures because the part can be held once and rotated so that the geometry is created.  Fixtures are time consuming to design and build and when considered alongside a requirement for special tools and/or tool extensions can significantly increase the overall cost of production.

Superior surface finishes and better part quality

Another advantage of 5 axis machining is that it enables shorter cutting tools to be used since the head can be lowered towards the job and the cutter oriented towards the surface.  As a result higher cutting speeds can be achieved without putting excessive load on the cutter so extending tool life and reducing breakages.

The use of shorter cutters also reduces the tool vibration that can result when machining deep cores or cavities with 3 axis machines.  This results in a higher quality surface finish reducing or eliminating the need for time consuming hand finishing.

CNC Milled Component using 5 Axis Technology

Complex components machined at competitive prices

At Presto Engineering our 5 axis machining capability means that we can be extremely competitive when quoting for your complex components.  We are always looking for new challenges so do upload your drawings and solid models here and we will get back to you with a quote.

If you would like further information on 5 axis machining or any other topic relating to CNC milling of aluminium machined components please get in touch at sales@prestoeng.co.uk or call us on 01865 883508 or contact us via the website.

For more information about Presto Engineering please visit our website here and if you would like a quote or to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

The post 5 is the Magic Number – Exploring 5 Axis CNC Milling first appeared on Presto Engineering.

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Jigs & Fixtures

At Presto we are constantly looking for ways to increase efficiency and streamline the manufacturing of aluminium precision machined parts.  The design of jigs and fixtures can have a significant impact on component quality and productivity.  Achieving the optimum design  is well worth the investment of a little extra time and care.

Jigs and fixtures  produce interchangeable and identical components.  They are unique tool guiding and work-holding devices designed specifically for machining and assembling large numbers of components.

In straightforward terms, jigs guide the tool and fixtures hold the work-piece in position but for the sake of clarity:-

• A jig is a work-holding device that supports, holds and locates the work-piece and guides the cutting tool. Its main objective is to ensure a high degree of precision and repeatability in component manufacturing.
• A fixture is a work-holding device that holds supports and locates the work-piece for a specific operation but does not guide the cutting tool. A fixture’s primary purpose is to create a secure mounting point for a work-piece.

Design Considerations/Principles for Jigs and Fixtures

At Presto we design and make Jigs and Fixtures for most of our CNC machining work. To ensure that we produce the highest quality aluminium components there are a number of issues we take into account :-

Locating Points

The position of the work-piece needs to be accurate with respect to tool guiding in the jig or setting elements in the fixture.  The aim is to minimise the time taken to insert and remove the work-piece into position.

Clamping Device

The clamping device should be as simple as possible without sacrificing effectiveness.  The strength of the clamp needs to be sufficient to hold the work-piece firmly in place and take the loads of the cutting tool.  This must be achieved without causing stress which can result in damage, marking or distortion to the component.

Fool Proof

Ensure work-piece and tool can only be inserted in the correct position.

Reduction of Idle Time

The design  needs to facilitate the loading, clamping and unloading time of the work-piece to  achieve  the minimum time possible

Weight

Keeping the weight  to the minimum without sacrificing rigidity will make them easier to use.

Handles

In some case the addition of handles can also enhance ease of movement

Advantages of quality jigs and fixtures

Investing time in ensuring that jigs and fixtures are of the highest quality is well worth the effort as it will impact the quality of parts produced.  Below are some of the advantages of superior jigs and fixtures:-

Quality

Good jigs and fixtures will reduce variability of dimensions of components and high volumes of parts can be manufactured of a consistent quality.

Productivity

Allows multiple parts to be held and machined together.

Cost

The increase in productivity and reduction of scrap will contribute to producing the most cost effective high quality precision machined components.

Investing time and effort into producing high quality jigs and fixtures which are thoroughly tested will pay dividends.  For manufacturers of aluminium precision machined parts like us at Presto, this level of diligence is an integral part of our production process.  Our goal is to provide our customers with high quality aluminium machined components at a competitive price and investing in good jigs and fixtures is a significant contributing factor.

If you would like further information on jigs and fixtures or any other topic relating to CNC milling of aluminium machined components please let us know at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like a quote or to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

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The post Jigs and Fixtures – The Foundations for Quality Aluminium Machined Parts first appeared on Presto Engineering.

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