The Boeing X-37B spaceplane is to begin executing a series of novel manoeuvres, called aerobraking, to change its orbit around Earth, the US Space Force has announced.

Easily access valuable industry resources now with full access to the digital edition of Canadian Fabricating & Welding.

Walter has now launched its new X·treme Evo Plus drill from the DC180 Supreme product family that is now available up to 8XD for the first time.

OSG’s HY-PRO® VGM variable geometry end mill series is available in 5-, 6- and 7-flute line-ups with multiple lengths of cut, with both square and corner radius variations. Featuring geometry and coating that reduces vibration, maintains edge sharpness and tool rigidity, all while providing exceptional wear resistance.

Gardner Aerospace, one of Europe’s largest manufacturers of aerospace components has been able to significantly improve productivity and machine efficiency. With cutting tool support from MSC Industrial Supply Co., the company has reduced machine hours by 81%, resulting in significant cost savings.

At Gardner’s manufacturing site in Broughton, North Wales, where structural components are made for aerospace OEMs, MSC’s applications engineer, Stuart Wiezniak, has provided cutting tool support to ensure improved efficiency and cost-effectiveness across production. Having previously worked with the manufacturer at its Hull facility, where MSC delivered crucial improvements in production efficiency, Wiezniak was tasked with working closely with the Broughton team to yield similar results.

With an annual production output of 7,920, Gardner’s Haas S20Y turning centre has been a critical piece of machinery in a daily three-shift operation. However, recognising the machine’s constraints for this particular job, which required considerable material removal rates, MSC recommended the process be moved to a Dahlih 4-axis machining centre.

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As a result of the changes implemented by MSC, including the alternate machine tool, different configuration and more applicable cutting tools – selected from its range of more than 120,000 product lines from hundreds of vendors – Gardner is benefiting from significant productivity gains, increased machine availability and reduced cycle times.

Chipbreakers for the new inserts include TSF for finishing steel, TM for semifinishing steel, SS for finishing stainless steel, and SM for semifinishing stainless steel.

“Cutting tool strategies are always a balance of costs versus productivity rates,” Wiezniak concludes. “In this instance, the annual tooling cost increased by £321 per annum to £2,678, but we have slashed machine hours by 81% from 724 hours to 141 and the cost per part has reduced from £28 to £23. The total saving of £37,542 for this job not only absorbs the slight increase in tooling costs, but it also improves process reliability, frees-up machine capacity and man-hours and it improves component quality.”

Using a BT40 spindle taper and specially-developed fixture, the machine was successfully adapted to machine five parts in a single set-up, as well as utilising the fourth axis to rotate the parts 180° to machine the opposite side.

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The NeoMill-Alu-QBig indexable insert milling cutter from Mapal stands for top performance in high-volume milling of aluminium. The tool manufacturer thus offers a very economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

Keep up to date with the latest news, events, and technology for all things metal from our pair of monthly magazines written specifically for Canadian manufacturers!

Babcock International Group (Babcock), the defence company, has been awarded a two-year contract extension by the UK Ministry of Defence (MOD) to continue to provide technical support services across the UK armed forces.

“The first challenge was to ensure machine availability to move the part from the turning centre to a machining centre,” Wiezniak explains. “From there, we had the freedom to instigate process changes such as the five-part fixture for multiple part machining. Devising a platform for rigid machining was the foundation block and once this was in place, we could look closer at tooling strategies and subsequent savings.”

The inserts are available in a CVD grade T9100 for turning steel and CVD grade T6100 and a PVD grade AH600, both for turning stainless steel, along with two cermet grades, NS9530 and GT9530.

These smaller inserts incorporate the identical chipbreaker geometry and thickness of regular-sized inserts to maintain the same cutting performance at a depth of cut up to 0.12 in., the company states.

In celebration of World Space Week, Space-Comm Expo has announced visitor registration is now officially live and open for the London ExCeL, event, running 11-12 March 2025.

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Gardner Aerospace, one of Europe’s largest manufacturers of aerospace components has been able to significantly improve productivity and machine efficiency. With cutting tool support from MSC Industrial Supply Co., the company has reduced machine hours by 81%, resulting in significant cost savings. At Gardner’s manufacturing site in Broughton, North Wales, where structural components are made for aerospace OEMs, MSC’s applications engineer, Stuart Wiezniak, has provided cutting tool support to ensure improved efficiency and cost-effectiveness across production. Having previously worked with the manufacturer at its Hull facility, where MSC delivered crucial improvements in production efficiency, Wiezniak was tasked with working closely with the Broughton team to yield similar results. As a result of the initial improvements, Gardner has so far realised savings of almost £40,000 on a single job through a new tooling strategy which dramatically reduced machine hours. Gardner’s manufacturing site in Broughton, North Wales Building the foundations With an annual production output of 7,920, Gardner’s Haas S20Y turning centre has been a critical piece of machinery in a daily three-shift operation. However, recognising the machine’s constraints for this particular job, which required considerable material removal rates, MSC recommended the process be moved to a Dahlih 4-axis machining centre. Using a BT40 spindle taper and specially-developed fixture, the machine was successfully adapted to machine five parts in a single set-up, as well as utilising the fourth axis to rotate the parts 180° to machine the opposite side. “The first challenge was to ensure machine availability to move the part from the turning centre to a machining centre,” Wiezniak explains. “From there, we had the freedom to instigate process changes such as the five-part fixture for multiple part machining. Devising a platform for rigid machining was the foundation block and once this was in place, we could look closer at tooling strategies and subsequent savings.” Adapting a tooling strategy From a tooling perspective, MSC replaced the existing indexable ball-nosed tool used for the semi-finish process and replaced it with a Dormer Pramet 32mm diameter high-feed end mill with five inserts and four edges per insert. Applying inserts with Dormer’s M6330 coating grade, machining parameters were transformed beyond recognition. In addition, the new rough and semi-finish end mill was optimised to run at a 0.7mm depth of cut with a cutting speed of 180m/min. Subsequently, the material removal rate leapt from 6.64cm3/min to more than 50cm3/min. Now, with a 50mm diameter button tool used to complete the task, cycle times have plummeted from 5 minutes 49 seconds per part to just over 33 seconds. This includes 26 seconds of rough machining with the Dormer end mill and a seven-second cycle with the finishing tool, yielding Gardner Aerospace a saving of more than 5 minutes per part – a significant saving considering the annual quantities required. Delivering on results As a result of the changes implemented by MSC, including the alternate machine tool, different configuration and more applicable cutting tools – selected from its range of more than 120,000 product lines from hundreds of vendors – Gardner is benefiting from significant productivity gains, increased machine availability and reduced cycle times. “Cutting tool strategies are always a balance of costs versus productivity rates,” Wiezniak concludes. “In this instance, the annual tooling cost increased by £321 per annum to £2,678, but we have slashed machine hours by 81% from 724 hours to 141 and the cost per part has reduced from £28 to £23. The total saving of £37,542 for this job not only absorbs the slight increase in tooling costs, but it also improves process reliability, frees-up machine capacity and man-hours and it improves component quality.” www.mscdirect.co.uk

From a tooling perspective, MSC replaced the existing indexable ball-nosed tool used for the semi-finish process and replaced it with a Dormer Pramet 32mm diameter high-feed end mill with five inserts and four edges per insert. Applying inserts with Dormer’s M6330 coating grade, machining parameters were transformed beyond recognition. In addition, the new rough and semi-finish end mill was optimised to run at a 0.7mm depth of cut with a cutting speed of 180m/min. Subsequently, the material removal rate leapt from 6.64cm3/min to more than 50cm3/min.

Tooling manufacturer, Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC.

As a result of the initial improvements, Gardner has so far realised savings of almost £40,000 on a single job through a new tooling strategy which dramatically reduced machine hours.

Image

Now, with a 50mm diameter button tool used to complete the task, cycle times have plummeted from 5 minutes 49 seconds per part to just over 33 seconds. This includes 26 seconds of rough machining with the Dormer end mill and a seven-second cycle with the finishing tool, yielding Gardner Aerospace a saving of more than 5 minutes per part – a significant saving considering the annual quantities required.