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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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.

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Aluminium Finishing- At Presto we take responsibility for all aspects of your project from submission of 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 parts where appearance is key aluminium lends itself to stylish finishes such as anodising.  Durability is often a deciding factor particularly when parts are for outdoor use.  When parts will not be visible and are for indoor use they can have a range of cost effective treatments such as Surtec 650, Alochrom or Irridite.  Whatever your requirements we work with you to find the best solution for your component.

Below are a selection of finishes we offer:-

 Anodising

Anodising can only be carried out on aluminium and it is the most frequently requested finish by our customers.  It is an electrochemical process that converts the metal surface into a decorative, durable corrosion-resistant anodic oxide finish and can be dyed in a variety of colours and finishes.

Anodising is accomplished by immersing the aluminium into an acid electrolyte bath and passing an electric current through the medium.  A cathode is mounted to the inside of the anodising tank; the aluminium acts as an anode so that oxygen ions are released from the electrolyte to combine with the aluminium atoms at the surface of the part.  In brief, anodising is a matter of highly controlled oxidation which is an enhancement of a naturally occurring phenomenon.

Benefits of Anodising include:-

Durability – Most anodised products have a long life span so the finish needs to be durable.  Anodising is a reacted finish that is integrated with the underlying aluminium for total bonding and unmatched adhesion.  The anodised surface is very hard and as a result preserves and extends the life of the aluminium product.  Anodised aluminium is resistant to corrosion and well suited to a wide range of applications.

Colour Stability – The sealing process used in anodising results in your anodised part looking factory new for years.  Anodised surfaces provide good stability to ultraviolet rays, do not chip or peel and are easily replicated.

Ease of Maintenance – Scars and wear and tear from handling, installation, frequent cleaning and usage are virtually non-existent.  It is generally sufficient to clean anodised surfaces with mild soap and water to maintain the original finish although a mild abrasive cleaner can be used for more stubborn stains.

Aesthetics – Anodising offers a wide variety of colour and texture alternatives and allows the aluminium to maintain its metallic appearance.

Cost – A low initial finishing cost combined with minimal maintenance costs makes anodising excellent long term value.

Health and Safety – As the anodising process is a reinforcement of a naturally occurring oxide process, it is non-hazardous and does not produce any harmful or dangerous by-products.

Anodising Pre-Treatments

• Bead Blasting

Bead blasting is the process of removing surface deposits on metal by applying fine beads at high pressure using compressed air without damaging the surface.  It is a popular choice of finish with our customers and we have invested in new Bead Blasting and Graining equipment.

Machined aluminium parts end up with lines, swirls and etching on the surface as a result of the machining process.  To prevent these imperfections from translating through a coating or anodising the surface is always made uniform by bead blasting prior to applying the chosen finish.

The benefits of Bead Blasting include:-

Uniform Finish –A perfectly clean uniform finish is achieved on all shapes of component including 3D and curved.

Styling Options – By varying the bead size the surface finish can be altered to suit individual customer requirements.  The graining can be made coarser or finer and the finish matte or bright.

• Graining

Graining is the process of polishing ‘grit lines’ onto the surface that are uniform and directional in appearance.   It is achieved by polishing the surface with an abrasive grit belt.  The finish achieved will depend upon the coarseness of the grit used.  Graining followed by clear anodising will result in a natural finish.  This finish is particularly popular for trims and badges.

Industrial Paint Finishes 

There are two systems of industrial paint finishes for aluminium finishing; wet painting and powder coating. Both of these systems will offer a durable and corrosion proof coating, but the application of the component will determine which system is used.

• Wet Paint

Generally speaking wet painting is used where a durable high quality finish is required on visible surfaces that the end user comes into contact with. For example applications can range from machined front panels for high end audio equipment through to car bodywork. Finishes are wide and varied and range from high gloss through to matte, and there is also the ability to have soft feel rubberised and suede textures incorporated.

Wet paint is commonly applied using a spray painting method, which involves utilising an air-pressurised spray gun. The air gun is made up of three main parts; the nozzle, paint basin and air compressor.  Paint is mixed with compressed air and when the trigger is activated a fine spray is released.  Usually a coating will be applied by hand, although the process can also be automated.

• Powder Coat

Powder-coating also provides a very hard wearing and durable coating.  It is ideal for products that are subject to intense handling or products that do not require such a high quality finish.  A multitude of coatings can be specified such as satin, gloss, metallic, iridescent and matte.

Powder coat application is based on the principle of opposite electric charges being attracted to one another.  Powder particles are electrostatically charged as a result of passing through a charged spray gun and are then attracted to an earthed component. The part is then thermally cured in an oven and the result is a high resistance finish.

Screen Printing

Screen printing is used in Aluminium finishing to print text and colour graphics onto almost any component for example control panels, nameplates for machines, serial and model numbers etc.  It results in a durable print that cannot be scratched off easily and is resistant to corrosion and extremes of temperature and weather.

Anoprinting

Anoprinting is generally used for demanding applications such as industrial environments. The process of anodising opens up the pores of the aluminium, a printed dye is then introduced into the porous surface layer. The pores are then sealed, trapping the ink into the surface. It changes the chemical composition of the aluminium, forming a hardened layer which provides protection from corrosion, and increases resistance to wear and abrasion. The surface appearance is resistant to marking from fingerprints and makes for a functional and decorative label.

Laser Engraving

Laser engraving is a process  that is suitable for aluminium finishing it’s where a high heat laser beam physically removes the surface of the material by causing it to vaporise and creates a cavity.  If the metal has been pre-treated or coated, the laser will engrave away this top coating to reveal the metal finish below.  Engraving can be used to customise or personalise parts and is particularly good for high wear parts.

Laser Etching

Etching is a process where a laser beam uses high heat to melt the surface and the melted material expands and causes a raised mark.  It can be done on anodised or bare aluminium.

Laser Marking

Laser marking uses a lower power beam than laser engraving and etching and leaves the surface material intact.  It is achieved by moving a low powered beam across the surface which causes oxidation under the surface turning the material black.  The precise and repeatable nature of lasers allow for fine detail marking on small components.  Laser marking is used for identifying products for example bar codes, serial numbers and regulatory symbols.

The options for aluminium finishing are endless so please do call us on 01865 883508 or e mail us at sales@prestoeng.co.uk to discuss your project.

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

The post Aluminium Finishing first appeared on Presto Engineering.

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UK manufacturers are used to working in competitive markets as a result of Political events at home and overseas the UK faces a period of economic uncertainty.  It looks likely businesses will see raw material and component costs rise and the challenge will be delivering the same high quality products at a price the customer will pay.  Optimising product design for manufacture and assembly is a key contributor to managing costs and gaining a competitive edge.

As a manufacturer of machined aluminium parts we encourage our customers to involve us early in the design process.  It is well known that, although design costs consume approximately 20% of the total budget for a new project, typically 80% of manufacturing costs are determined by the design of the product¹.  However, the days of product design taking place in a vacuum are long gone!   Concurrent Engineering, a method of designing and developing products, in which the different stages run simultaneously, rather than consecutively, is the key to achieving a design suitable for cost effective manufacture and assembly.  Here are a few key points to consider²:-

Simplifying the design

Reducing the number of parts increases the probability of a perfect part, and reduces costs.  Fewer fabrication and assembly steps are required which gives the opportunity to integrate processes and reduce lead times.

Standardise and use common parts and materials

To minimise the level of inventory in the system and standardise handling and assembly operations.  An example of this in action is the VW Group³ chassis system which is used across a wide range of vehicles.  Known as the Modular Transverse Matrix (MQB)⁴ it is the standardisation of vehicle components and production processes and enables different models and brands to run on the same assembly line.

Design for ease of fabrication

Select materials compatible with production processes.  Working closely with Procurement colleagues can result in optimum material selection and sourcing at the best price.  Design for ease of fixturing and avoid unnecessary part features that involve extra processing effort and/or more complex tooling.

Design for easy and ‘mistake-proof’ assembly

By ensuring that the assembly process is unambiguous.  The ideal scenario is components that can only be assembled one way!  Threaded fasteners such as screws, nuts and bolts are time consuming to assemble and difficult to automate.  It is worth considering the use ‘snap-fit’ attachment methods.

Design for automated production

By ensuring that the product is easily assembled manually.  Automated production is less flexible and considerations vary depending on whether flexible robotic assembly or high speed automation is to be used.

As usual we would love to hear what you think?  Are you working closely with your designers?  Have your raw material and component costs risen since Brexit?  Please give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

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

References   

¹Claudio Favi, Michele Germani, Marco Mandolim, 2016. Design for Manufacturing and Assembly vs. Design to cost: toward a multi-objective approach for decision-making strategies during conceptual design of complex products. [pdf] Available at: http://ac.els-cdn.com/S2212827116305741/1-s2.0-S2212827116305741-main.pdf?_tid=18f28f0a-ed44-11e6-a391-00000aab0f27&acdnat=1486478921_9a20816b1f8c938f9ffd5d9556be447f [Accessed 8 February 2017].

²NPD Solutions, 2014. Design for Manufacturability/Assembly Guidelines. [online] Available at: http://www.npd-solutions.com/dfmguidelines.html [Accessed 8 February 2017].

³Dr James Moultrie, University of Cambridge, 2015. A holistic view of design for manufacture [pdf] Available at:

http://www.ifm.eng.cam.ac.uk/uploads/News/2012/15_Feb_Design_Icons_event_comes_to_IfM/DfMevent15-2-12.pdf [Accessed 8 February 2017].

⁴Volkswagen UK, 2016. Modular Transverse Matrix MQB [online] Available at http://www.volkswagen.co.uk/technology/modular-transverse-matrix-mqb [Accessed 8 February 2017]

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Is the future of UK Manufacturing in Robotics and Automation?

In 2012 the UK was ranked 19^th worldwide in terms of Robot density in the manufacturing sector with a level barely above the global average.  As an example the UK automotive industry is functioning with half as many robots as used in Germany, often cited as the European gold standard bearer for automation¹.

How has the UK been left behind?  It boils down to a lack of investment compared to other developed economies and the Office of National Statistics (ONS) has stated that the UK’s lack of improvement in post war productivity is “unprecedented”².

Germany and Japan are highly automated in manufacturing and if the UK were at the same level it is estimated productivity would increase by as much as 22% and long term employment by 79%. BMW’s Mini Plant in Oxford and Jaguar Land Rover’s plants at Solihull and Halewood are examples of soaring productivity as a result of heavy investment in robotics and automation³. But they are not the general rule in UK manufacturing.  Bearing in mind this technology is open to all markets what must we do to increase our global competitiveness?

In this article the terms ‘Robotics’ and ‘Automation’ are used interchangeably as businesses will utilise the most effective technology to achieve their goal.

In late 2015 Barclays issued a report, ‘Future-proofing UK manufacturing’ based on economic analysis conducted on behalf of YouGov.  It includes results of a survey of UK and German manufacturers and, by the use of economic modelling, shows the potential future impact of investment in Robotics and Automation¹.  The ‘top line’ suggests that if the UK invested £1.24bn in robotics and automation over the next 10 years it could add £60.5bn to the economy¹.  But how do those statistics impact an average UK manufacturing business and what has stopped them investing in automation?

Some key barriers to investment identified are:-

• Lack of funds for short and long term investments
• Prioritising other capital investment projects
• Concerns over the level and time of ROI
• Lack of support and advice about making the decision to automate

The size of business impacts the number investing, for example:-

• 71% of businesses with a turnover >£10m have invested in Robotics and Automation
• 21% of businesses with a turnover <£1m have invested in Robotics and Automation

Finally the type of business impacted the level of investment.

Sample business sectors with higher levels of investment in Britain:-

• Heavy Industry
• Medical Devices
• Building Products
• Automotive and transport

Sample business sectors with lower levels of investment in Britain:-

• Printing and Packaging products
• Textiles and clothing
• Wood and paper products

The trend is for businesses to increase investment in the next 2-3 years with the focus on improving efficiency and output.  This includes reducing production time, improving quality and plant flexibility which can result in a 20% increase in productivity³. However, overcoming the barriers to investment and implementation can be a challenging prospect in addition to the daily demands of a manufacturing facility.  Businesses want good technical support from their suppliers throughout the process from knowledgeable and responsive staff.

For smaller businesses the dilemma can be identifying the optimum time to invest and accurately estimating the period to achieve full return on investment (ROI).  The Government is maintaining the Annual Investment Allowance (AIA) for 2016 at £200,000 which although unlikely to be a sufficient incentive to make a business ‘take the plunge’ it may be enough to make the first years’ tax bill less painful⁴!  What is clear is that businesses, irrespective of size, are looking to the government for financial support in the form of grants and loans.

The new Prime Minister, Theresa May, is promoting a ‘Modern Industrial Strategy’ for Britain with a focus on research and development and she has committed the Government to significant investment.  In addition the Government will launch an “Industrial Strategy Challenge Fund” to back priority technologies such as robotics and biotechnology⁵.  However, many UK businesses believe that the Government should do more to help existing businesses improve their competitiveness in the global arena through Automation.

Is your business automated? If so, how did you find the implementation process?  If not, what are your plans for automation?  We’d love to hear your thoughts so give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

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

References 

 ¹Barclays Corporate, 2015, Future-proofing UK manufacturing. [pdf] Available at: https://www.barclayscorporate.com/content/dam/corppublic/corporate/Documents/research/automation-report.pdf [Accessed 21 December 2016].

²Office for National Statistics (ONS), 2015. Labour Productivity: Q4 2014. [online] Available at: https://www.ons.gov.uk/employmentandlabourmarket/peopleinwork/labourproductivity/bulletins/labourproductivity/2015-04-01 [Accessed 21 December 2016].

³The Manufacturer, 2016, Annual Manufacturing Report 2016. [online] Available at: http://www.themanufacturer.com/reports-whitepapers/annual-manufacturing-report-2016/ [Accessed 21 December 2016].

⁴HM Revenue & Customs, 2015, Annual Investment Allowance: permanent increase to £200,000. [online] Available at: https://www.gov.uk/government/publications/annual-investment-allowance-permanent-increase-to-200000/annual-investment-allowance-permanent-increase-to-200000 [Accessed 21 December 2016]

⁵Prime Minister’s Office, 21 November 2016, PM Announces major researchboost to make Britain the go-to place for innovators and investors. [online] Available at: https://www.gov.uk/government/news/pm-announces-a-2-billion-investment-in-research-and-development [Accessed 21 December 2016].

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