Die casting company installs two more high-speed machining centres

Whitehouse Machine Tools Ltd

In medium volumes, there is little difference between the cost of producing machined castings in China and in the UK

Zinc and aluminium high-pressure die casting specialist RD Castings has used Japanese-built, high-speed, twin-pallet machining centres from Brother since 1989 and currently has nine of them adding value to its products in two machine shops in Mildenhall, Suffolk. Since the mid-90s, the 30-taper machines have replaced manual milling, drilling and tapping, which was both labour intensive and subject to quality variation.

Running the company are siblings Anthony and Michael Pateman, who were interested when Brother’s UK agent, Whitehouse Machine Tools, suggested they see a demonstration of the machine manufacturer’s new ISO control with 12-inch colour LCD screen, the CNC-C00, a significantly faster and more user-friendly CNC system fitted to its latest machines.

After they visited the agent’s Kenilworth showroom and technical centre at the end of 2016, they came away not only with up to date information on the new control’s capabilities, but also having ordered another Brother machining centre, a Speedio R650X1 with Nikken rotary 4th axis. It was not their intention before the visit, but the machine was so productive and such a good fit for RD Castings’ needs that they placed the order on the day and invested in a second identical model within six months.

Numerous facets make the machine particularly applicable to machining light castings, one being its outstanding speed. Workpiece changeover is completed entirely within the 3.4-second rotation of the twin-pallet Quick Table, as the 21-pocket magazine’s 0.9 second tool change time, 50 m/min rapids in X Y and Z, and rotation of the 4th CNC axis are carried out simultaneously.

The first tool is ready to cut the next component immediately it arrives in the machining area and little time is wasted on each subsequent exchange of the cutter due to the rapid tool-to-tool time and spindle acceleration from zero to 16,000 rpm in 150 milliseconds, with similarly fast stop time.

Michael Pateman commented, “The speed of tool change on the R650X1 mirrors that of our Brother 324N and R2A machine models, where the tool carousel encircles and travels with the spindle, which does not have to move away to pick up a new cutter as on the Brother TC32A and 32B machining centres that we also have on-site.

“It results in very high productivity that is enhanced by faster processing of existing programs in the new CNC-C00 control. For example, we recently reduced a 3.5-minute cycle by 20 seconds with no change to the original program. If we are machining say 20,000-off parts annually, the saving runs into thousands of pounds.”

Anthony Pateman pointed out another advantage of the R650X1, namely the generous axis travels of 650 x 400 x 305 mm in X, Y and Z. The table accepts RD Castings’ 500 x 350 mm base plates on the trunnion fitted to both machines, allowing multiple components to be fixtured for 2-axis and 3-axis machining, relieving the load on the 324Ns and R2As which are always filled with work.

He added, “There is a trend towards larger castings these days and we have just installed a 500-tonne casting machine to meet the requirement. In order to machine them, the ability of the R650X1 to swing our 400 mm diameter parts in the rotary axis means that we are often able to finish these bigger castings in one hit and save on a second set-up operation, which hugely decreases cost of production.”

To underline this comment, he pointed to a casting of about the size that used to need a second operation but is now machined in one 4-axis process, saving 70 pence per part.

Simon Hale, CNC machine shop manager, stated that productivity of another part – an aluminium die cast housing for the rail industry – has been nearly doubled using the larger machine compared with the other Brother models with similar tool carousels. 17 castings per hour were drilled and tapped using 12 tools on the latter machines, whereas using a trunnion fixture on an R650X1, 32 parts per hour come off the machine after each pallet rotation and just eight tools are needed.

The increase in output is partly because, by routing coolant at the uprated 30-bar pressure on RD Castings’ latest machines through an indexable-insert drill rather than employing a twist drill, it is possible to produce larger holes above 18 mm diameter in one spindle movement, rather than having to spot and then peck drill the holes multiple times.

Michael Pateman asserts that manufacturing costs are increasing in Asia while the lower pre-Brexit value of the pound is helping UK competitiveness.

He summed up, “By employing ultra-high-speed machining techniques on 30-taper rather than 40-taper machines, with extensive use of polycrystalline diamond inserts clamped in dynamically balanced tool holders, the cost of producing a casting is now about the same in Mildenhall as it is in China – and we are winning back business as a result.

“The latest Brother Speedios with their larger working envelope have added considerable versatility to our shop floor, as they can economically machine anything from the simplest, smallest casting up to the largest and most complex. Productivity is also up due to the faster control and by allowing more flexible production planning.”

“All of our Brother machines work flat out eight hours a day and their speed, accuracy and reliability are fantastic. Coupled with the high level of support from Whitehouse, it has been an unbeatable package for us.”

“Quality machines for quality parts ” – Reginson Engineering turns to Ward CNC

T W Ward CNC Machinery Ltd

Reginson Engineering’s unequivocal need to use “quality machines to produce quality components” has seen a batch of ten Hyundai Wia vertical machining centres and CNC lathes installed to help the company meet the demands of an ever-increasing order book for aero-engine components.

Steve Hatch, Director of the Nuneaton-based specialist sub-contract machinist, also says that the extra capacity of the new machines was urgently needed “and in addition to the competitive pricing offered by T W Ward CNC Machinery (Ward CNC), all the machines were available on a very quick delivery – within three weeks”.

He adds: “In business terms, therefore, the immediate availability of additional high-class yet cost-effective CNC production machines met all our needs.”

The six turning machines (four two-axis L210A models and two E200s with c axis) and four vertical machining centres (F400 models), were available from stock from Ward CNC, Hyundai Wia’s exclusive UK and Ireland agent.

They joined an impressive portfolio of state-of-the-art machines and production equipment on Reginson’s 25,000 ft2 shop floor, which also boasts other Hyundai Wia models and Takisawa turning centres, also available from Ward CNC:

  • Takisawa Taiwan – four EX106, two EX108, one EX110 with live tooling, one EX310 and four EX308s with live tools; and
  • Hyundai Kia turn-mill centres – three SKT 100s and two SKT 200s.

The new machines are being used to perform what Mr. Hatch describes as “fairly straightforward” milling, drilling, boring and turning operations on a variety of workpieces including elbows and T pieces in materials such as stainless steel and Inconel.

“Workpiece complexity aside, however, we have to ensure that every component we produce is machined to the highest levels,” he adds. “So, to ensure we have quality output, we must use quality machines.”

Supplying customers also in the military, nuclear, motor sport, oil and gas, and rail industries, for example, privately-owned Reginson Engineering quickly gained a global reputation for world-class machining after its establishment in 1995. Today it employs more than 80 staff at the Nuneaton site.

Indeed, its burgeoning order book has also led to the establishment of a sub-contract machining facility in Pune, India, where 45 staff are employed, to meet the continual rise in orders specifically from the aerospace sectors.

With a growing focus on aerospace work, approvals were soon gained from organisations such as Rolls-Royce, Eaton and Godrej.

With BS EN 9100 accreditation, as well as AS9100 Rev D and (Rolls-Royce aero division) approvals, key customers include Pattonair, Meggitt, UTC and Parker Hannifin.

“Having experience of Ward CNC’s service and back up – and of the reliability of the machines it supplies – meant we knew exactly where to turn when we wanted much-needed capacity quickly,” Mr Hatch concludes.

“This latest investment tranche to meet a constantly rising order book is testament to our policy of developing leading–edge manufacturing methods and continual investment in new machinery and personnel,” he says. “This helps to ensure we remain focused on maintaining customer support by delivering quality products on time.”

ABB’s innovative flash-charging technology goes live

ABB

First e-buses with ABB’s world-record flash-charging technology go into commercial service.

ABB’s 20-second flash-charging technology was a hot topic today as two articulated electric buses, the first of their kind in the world, went into service on bus line 23 in Geneva. It takes less than 1 second to connect the bus to the charging point on an overhead high-power charging contact when it pulls into selected stops and tops up its batteries while passengers embark and disembark. The complete fleet of 12 emission-free buses links the airport with the city’s suburbs. Through optimal energy management, the system can save as much as 1,000 tons of carbon dioxide on a line covering 600,000 kilometers per year.

ABB is a pioneering technology leader in electrification products, robotics and motion, industrial automation and power grids, serving customers in utilities, industry and transport & infrastructure globally. Continuing more than a 125-year history of innovation, ABB today is writing the future of industrial digitalization and driving the Energy and Fourth Industrial Revolutions. ABB operates in more than 100 countries with about 136,000 employees.

ABB achieves breakthrough with world’s most powerful HVDC transformer

ABB

ABB writes next chapter in electrical history as transformers and key equipment for world’s first 1,100 kilovolt (kV) project in China pass stringent tests

ABB has set another pioneering innovation record with the successful testing of the low and high voltage units of the world’s most powerful ultrahigh-voltage direct current (UHVDC) transformer. The +/-1,100 kV (1.1 million volts) UHVDC transformer, developed and manufactured in close collaboration with State Grid Corporation of China (SGCC), has successfully passed a series of type tests, paving the way for the implementation of the Changji-Guquan UHVDC link, which will transmit power from the Xinjiang region in the Northwest, to Anhui province in eastern China.

Changji-Guquan, the world’s first +/-1,100 kV UHVDC link will set a new world record in terms of voltage level, transmission capacity and distance. It will be capable of transporting 12,000 megawatts of electricity – the equivalent of 12 large power plants and 50 percent more than the +/- 800 kV UHVDC links currently in operation. Transmission distance will be extended from around 2,000 kilometers (km) to over 3,000 km, enabling the integration and transmission of remote renewables on a much larger scale.

When fully operational this UHVDC link will be able to feed eight 500 kV and two 1,000 kV AC lines – delivering power equivalent to twice the average annual power consumption of Switzerland. ABB’s latest breakthrough also makes it possible to connect +/-1,100 kV DC with 750 kV UHVAC links for the first time. In addition to the transformer, ABB has also developed and successfully tested a range of other key +/-1,100 kV components, including converter valves, bushings and DC circuit breakers.

“In addition to transporting more power across longer distances with lower losses, this breakthrough will enable the interconnection of AC and DC grids and support the future linking of regions and countries.” said Claudio Facchin, president of ABB’s Power Grids division. “It reinforces our pioneering technology leadership in HVDC transmission and reaffirms our close collaboration with SGCC, as we enable a stronger, smarter and greener grid”.

“The Changji-Guquan +/-1,100kV project is a major technical step-up making it the world’s highest DC voltage. The transformer is a key element of this link and we are pleased that the first of these landmark transformers have passed critical tests and exceeded expectations. I would like to congratulate the teams from ABB and SGCC on this successful achievement” said Mr. Liu ZeHong, Executive Vice President, SGCC.

China has major consumption centers in the east, while a significant amount of its energy resources are in the west and northwest. The expansive geography and increasing demand have prompted the build-up of ultrahigh voltage links to increase transmission capacity while minimizing losses.

ABB pioneered HVDC technology more than 60 years ago and is the global market leader with over 110 HVDC projects, representing a total installed capacity of more than 120,000 megawatts – around half of the world’s installed base. UHVDC transmission is an advancement of HVDC and represents the biggest capacity and efficiency leap in over two decades. In 2010 ABB supported SGCC with the Xiangjiaba-Shanghai project, the world’s first +/- 800 kV UHVDC link to go into commercial operation.

AMRC Castings unveil largest ceramic shell titanium casting created in Europe

AMRC

The Castings Group of the Advanced Manufacturing Research Centre (AMRC) has unveiled the largest ceramic shell titanium casting ever created from a single pour in Europe.

The casting is a milestone test piece and will become a showcase for development of the AMRC’s titanium casting facility which became operational earlier this year.

The large-scale, near net shape casting is an industrial centrifugal pump housing, used for highly corrosive applications in the chemical and petrochemical sectors. It was poured from a 680kg melt with a 200kg finished part weight.

AMRC Castings’ General Manager, Richard Cook, said: “This test piece is a significant step forward for us and the UK as a whole. We are the UK’s only titanium melting facility and this achievement, sends a clear signal that the country is open for business for large-scale titanium casting.”

“Global capacity for titanium castings, particularly of this size, is scarce – indeed it has actually decreased in recent years, despite growing demand. There is a clear need for this kind of capability and our research and development will underpin the ability for the UK to remain competitive in a global market.”

AMRC Castings is now working towards its goal of pouring over 1000kg of titanium for a 500kg part-weight centrispun casting by May 2018, testing the boundaries and limits of their Retech consumable electrode castings furnace.

The furnace has three interchangeable crucibles capable of melting titanium for castings weighing up to 500kg and 2000mm in diameter by 2500mm in length.

The group is already dealing with enquiries from companies wanting to exploit the technology and are currently conducting paper studies and piloting the first research projects.

Principal Metallurgist, Matt Cawood, said: “The AMRC are currently engaged in several projects looking to improve capability and technology to enable more complex, higher integrity components to be designed for manufacture with improved metallurgical quality and increased dimensional accuracy.”

“Having the ability to pour large-scale castings as part of a research and development activity combined with the surrounding facility of industry-scale equipment and technical expertise is a unique offering that is drawing in many of the world’s largest users of titanium castings to work with us.”

A cut above the rest: the western world’s oldest scissor manufacturer develops sharp new generation of blades after teaming up with AMRC

AMRC

William Whiteley & Sons (Sheffield) Ltd, the family owned scissor manufacturer which has been in operation in Sheffield since 1760, has recently teamed up with the Advanced Manufacturing Research Centre’s Design and Prototyping Group (DPG) to create an innovative new state-of-the-art design for their hand-crafted EXO range of scissors.

William Whiteley’s, the oldest documented scissor and shear manufacturer in the western world, are world-renown producers of professional and industrial hand-made scissors.

After attending the Advanced Manufacturing Show in Birmingham in 2015, scissorsmiths and company directors Jeremy and Sally Ward (neé Whiteley) envisaged a new way to manufacture their scissors, but found to make the improvements was proving cost and labour intensive.

“Due to being a small family-run company, we don’t have our own in-house design team. The directors have therefore designed many new products over the years, often with input from our skilled craftsmen,” said Jeremy.

“We approached the world-renowned AMRC, which is on our doorstep here in Sheffield, and with the help of their engineers we were able to develop our ideas and sketches into professional computer aided designs (CAD) ready for production.”

The company had ambitious plans to transfer the method of manufacture for their EXO scissors to an investment-casting route, which would give them the required surface finish for their new product.

AMRC Project Engineer Mike Locking said that for a small company to invest in untested designs and new production tooling, it can be an expensive risk: “Utilising the skills and capabilities we offer ensures designs can be effectively proved out before investing in the equipment needed to upgrade a manufacturing process, minimising the risk.

“We worked with scan data of the traditional scissors to produce detailed CAD and graphical renderings of the new design and use rapid prototyping technology to prove out the designs before the company invested in expensive new tooling.”

Jeremy said: “The assistance of the AMRC has been vital to help us realise the perfect design and ergonomics of the new scissors. They produced 3D printed production-quality prototypes of the handles and blades for us to test. Their input was critical for helping us mitigate the risk of launching a new product.”

The company is now celebrating after exceeding an initial target of raising £54,000 through crowdfunding to allow production of this new generation of scissors, which are due to start shipping in May 2018.

Robots will set us free

TM Robotics

Tom Watson, deputy leader of the Labour party, will soon launch the final report of the Future of Work Commission, which has concluded that we should not fear the “march of the robots”. The report is a welcome change the typical narrative that has painted the rise of automation as something that will result in the death of the human workforce. Here, Nigel Smith, CEO of industrial robot provider, TM Robotics, explains why businesses need to be smart about how they invest in automation technology.

The Future of Work Commission’s report concludes that Britain’s low productivity, falling wages and inequality are down to poor government decisions, not automation. It also states that the UK’s financial system is not doing enough to fund high technology sectors.

These findings, along with Tom Watson stating “robots can set us free”, are the authoritative message that the automation sector needs to erode potential panic that robots will replace the human workforce. It is a welcome change from the typical scaremongering narrative that has resulted in 70 per cent of Americans being afraid of robots performing jobs humans currently do.

This should be a fresh start for the development and adoption of automation technology. However, businesses still need to be smart about how they invest in such technology. Just as this report is calling for sensibly targeted government investment to use the technology revolution to reverse the UK’s economic decline, manufacturers have to be just as targeted and sensible in selecting the robots to enhance their processes.

It’s easy to buy into the belief that upgrading to new automated processed requires a massive capital investment in the newest technology. This is why you can’t go to a trade show, read an article about robots or talk to anyone in the manufacturing and engineering sector without hearing about why you should buy a collaborative robot.

While this technology is exciting, it is not yet developed to the point of being effective enough to deliver the performance and return on investment to make it a smart investment for everyone. Industrial robots, such as SCARA, 6-axis and Cartesian robots, are better suited to keep up with demands of manufacturing processes.

Collaborative robots are not currently capable of performing to the speeds needed by most manufacturers, and incorporating them into an existing production line is a complex and costly process. Industrial robots will fit in easily and cells can be tailored to perform incredibly complex tasks quickly, without the need for a human to intervene or ‘train’ them.

As Watson said, “robots can set us free”, but only if we’re sensible about the robots we invest in.

Digitalization — not just for big business

ABB

New technology is making digital solutions affordable for SMEs

When cellphones were first released in the mid-1980s, a handset would set you back $4000 — the equivalent of almost $10,000 today. Here, Markus Brettschneider, Group Senior Vice President and General Manager for Global Food & Beverage applications for ABB, explains how smaller food manufacturers can take advantage of low-cost digital technology.

When the first cellphone was released in 1983, this breakthrough technology was reserved for high-ranking business people and the social elite. Yet, decreasing technological costs have led to cellphones becoming arguably the most common technology available today. In fact, the UN’s 2014 telecommunications figures revealed that there are almost as many cellphone subscriptions as there are people on Earth.

This is indicative of a technological trend known as quality-adjusted price, which ties closely into the concept of Moore’s law. As technology rapidly develops at a pace that leads to significant performance increases year on year, the cost of that technology decreases at a similar pace.

This presents an important opportunity for smaller businesses to take advantage of newer technologies that were previously only accessible to large companies. In the food production industry, for example, there has been a significant increase in the adoption of digital technologies and software among larger businesses. Yet, food manufacturing companies of all sizes can tap into the productivity and efficiency benefits offered by digitalization.

The digital food plant

While equipment and robotics have been the key drivers of plant improvement in past decades, the rise of the industrial internet of things (IIoT) has placed greater importance on software and insight. In particular, many plant managers now use digital solutions to monitor the status of equipment to mitigate performance problems.

For example, most food processing plants will have automated at least one part of the production line with a conveyor system. As with any piece of equipment, parts of this system will gradually wear down from repeated use over time. For critical components such as the motor, this leads to a slow decline in performance and risks downtime due to breakage.

Plant managers must therefore undertake predictive maintenance to address any issues before they become problems. To do this effectively, plant managers must have accurate performance data from the conveyor’s low-voltage motors.

Rather than invest in new systems that feature IIoT functionality, businesses can install multi-function sensors to collect and analyse performance data.

For example, the ABB Ability Smart Sensor for motors allows engineers to digitalize food production plants with minimal expenditure. These sensors fit directly onto the motor’s frame and monitor key performance factors such as temperature and vibration. This data is transmitted to the cloud, where it is analyzed and reports are generated for plant engineers.

What the data provides is new insight into the health of motors used in production, enabling a shift from reactive maintenance to predictive maintenance. With a simple “stop light” system of green, yellow and red lights, fleet motor status is simple to assess.

Just as cellphones are no longer exclusive to the likes of CEOs of listed companies, digitalization is not reserved for large food production businesses. By investing in the right equipment, plant managers can start integrating the benefits of digital technology at a pace and budget that meets their production.

 

New tools for milling small threads

Horn

A new thread milling system, designated DCG, has been developed by Horn for producing M1 to M2.5 metric ISO threads DIN 13 – 20. The solid carbide, single-row, coated milling cutters, which have extremely sharp edges and are suitable for universal use, are available as standard for producing a thread length up to 2 x D. They demonstrate their special capabilities and efficiency when machining steels, stainless steels, cast iron, non-ferrous metals and in particular hard-to-cut materials used in the medical sector, for example.

DCG solid carbide mills have been proving themselves in the production of clean, high quality threads from M3 to M12 for many years. As the single-row milling cutters can be used for different pitches, a high degree of flexibility is provided.

Davturn enters new turning arena with latest Miyano BNE-51SY6 installation creating a greater competitive capability

Citizen Machinery UK Limited

Davturn, a small family-owned precision sub-contract machinist based in Bromsgrove has found increasing its production capability by installing a Miyano BNE-51SY6 turn-mill centre has added fuel to the burning desire to expand the five-people business into new larger premises.  As a result, managing director Mark Birley maintains, such has been the impact of the new machine that moving premises will then allow further Miyano installations by Citizen Machinery UK to increase its operational capability.

He said: “We installed the multi-axis 51 mm bar size Miyano BNE-51SY6 in June to join our existing Miyano BNA-42DHY which had already proven to be an outstanding success for the business since its installation in 2012.  At that time it enabled us to increase the size of bar we machine from our bank of five sliding head machines which limited our capacity to 32 mm. Now, with a 51 mm capacity this has immediately brought in a host of new orders.”

Mr Birley has been entrenched in turned part machining since he left school which led him to take his skill and set up Davturn 13 years ago basing the business on his experience in cam autos.  He bought his first CNC machine in 2007 which set the firm on its steady growth pattern and in the same year was joined by his son Matthew.  Matthew had decided he would rather have a longer skill-based future in machining than he would as an early career footballer when he played for Premier League side Birmingham City.

Indeed, under his father’s training he progressed to become a director of Davturn having learnt very quickly to become a highly skilled programmer and machine setter.  The firm also has two apprentices who, like Matthew, are being taught how to competitively apply and use technology involved in modern machining techniques.

Today some 20 active, mostly Midlands-based customers from sectors that include hydraulics and pneumatics, electrical, door-closure, fastener, construction, vehicle and rail as well as producers of control cabling.  This means Davturn faces a broad brush of component types from batches of 1,000 to almost continuous production of 500,000 quantities with cycle times varying between 15 secs and 5 mins.  Materials too vary from plastics to aluminium and high grade steels.

Since its installation, the BNE-51SY6 has not stopped producing components with the machine running seven days around-the-clock.  During the night and weekends, machine monitoring creates a call-out and immediate return to the workshop.  Said Matthew Birley: “The capability of the machine to hold so many tools on the two 12-station all-driven turrets means we can easily accommodate a suite of common tooling and rarely need to change a toolholder.  As a result, resetting is generally prepared and quick, most operations take less than 40 mins which helps keep our utilisation of the machine very high.”

He then explained how he uses the latest Citizen Wizard programming aid for both Miyano machines.  “This certainly enables new multi-featured parts, often involving difficult materials such as high tensile EN16T and EN24T, 303 austenitic and heat-treatable bearing Grade 404-C stainless steels to be efficiently programmed with good balance to the cycle between the two spindles.

Matthew Birley then follows on to describe one part produced in a 2,000 batch out of 25 mm EN16T bar for use in truck suspensions.  “We held 0.025 mm in the bore and 0.02 mm on the outside diameter which has a 0.8 CLA surface finish without any interruptions for adjustment.”  The part involved all tools being able to be used in overlapping operations between the two spindles and two turrets and as he said:  “… with the power available and the inbuilt rigidity of the machine it was a very straightforward to achieve a totally balanced machining cycle between each spindle.”  The part involved turning, drilling and counterboring, the rolling of an M10 internal thread, the milling of an 18 mm hexagon that were all completed in a 2 min cycle.

The Miyano BNE-51SY6 has been developed for single cycle machining with the ability to cut with three tools simultaneously overlapping when needed at both ends of a workpiece.  This is aided with the high rigidity of the 7.8 tonne machine that features boxway slides.  It has a 15 kW main and 7.5 kW secondary spindle both having maximum speeds of 5,000 revs/min.  The machine has the advantage of 12-station all-driven turrets.  As Davturn has found, this level of power to the driven tools of 2.2 kW delivering 25 Nm of torque and speeds of up to 6,000 revs/min has enabled cross machined features to be very effectively produced.

Having the flexibility of the new BNE has also helped win a contract involving 1,000 sub-assemblies and part production a month to produce windscreen wiper assemblies for the railway industry.  Here a range of component sizes in 303 stainless steel benefitted from the easy to set balanced machining cycles involving drilling, turning, boring and threading M26x1 each end with 45 mm lengths using both spindles.  “This capability was an important factor in establishing a competitive price to win and succeed in the contact,” said Mr Birley.

As Mr Birley commented: “Investing in the Miyano and with the level of support from Citizen’s application team means we are now riding a high.”  He then adds details of a further contract won following the machine installation. This involves a six part series of hydraulic valve sleeves complete with spools between 16 mm and 30 mm diameter in 440-C stainless steel.

He said: “We are able to machine the largest of these in under 5 mins with the most complex having 11 grooves in the outside diameter and 50 holes pitch drilled 5 mm diameter from the grooves into the bore which has 0.05 mm tolerance.  Because we are able to simultaneously combination gang drill the holes using both turrets and fully deburr in-cycle we are achieving a totally different capability that we could never have even dreamt about before.