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DMG Mori CLX 450 for Hallam

Hallam is continuing to invest in leading edge CNC technology with the acquisition of a new DMG Mori CLX 450 V4 turning centre to extend the capability of the machining unit. The 450 will be delivered in January 2020 and installed alongside two Mori CMX 800V vertical machine centres purchased new in 2019.

Simplicity and speed in setting up the machine for a wide range of tasks was a major consideration for Hallam and the Fanuc controls allow easy programming of the Y axis and live driven tooling with C axis, providing complex turning capability. The verification and graphics checks ensure a reliable milling and turning toolpath.

The machine removes the need for turning and milling operations on different machines and many components will be completed in one hit. As well as manufacturing parts around 20% quicker, Hallam will save handling and setting costs, and fixtures for different operations will largely be eliminated.

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Hallam Offers State of-the-art architectural powder coating system

Independent trials have confirmed that Hallam can now offer market leading powder coating with powders that have significantly longer gloss retention and resistance to colour change combined with maximum film integrity to ensure long term cosmetic and functional protection.

The trials were undertaken in accordance with ISO 4892-3 and ASTM G154 by an independent professional testing house and simulated 10 years exposure to Caribbean sunshine. The test report conclusions were that “the exposure to UV radiation had no noticeable effects on the colouring or surface finish of the components”.

Products powder coated using the system are now available commercially from Hallam. Please contact Rob Pickersgill, 07720591991 anytime, for full details.

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Additional new DMG VMC for Hallam

Hallam’ s quest to implement state-of-the-art technology in all manufacturing process  areas continued with the installation in April of a further DMG Mori CMX 800V vertical machine centre, primarily for use within the  machining operations unit. This follows the acquisition of a further Frech DAK 350 diecasting machine in December 2018, creating substantial additional capacity across common technological platforms within the two process areas.

MD Rob Pickersgill explained; “We are standardising on Frech diecasting and DMG Mori machining equipment so that the maintenance overhead is manageable. The main consideration however is the outstanding quality of the two platforms, which has already driven our ISO 9001 BSI Quality KPIs to levels much better than target. As a consequence capacity, turnover and margins are all now much improved, and will continue to do so. We have ambitious plans for the future.”                 

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Hallam Apprentice progresses to Degree-level course with AMRC

Hallam uses state-of-the-art CNC machinery in its foundry, machining centre and powder coating factory and apprentices trained at the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) are a key element of the workforce needed to work with this type of equipment.

Recruitment is facilitated by the AMRC, which invites applications from prospective apprentices and helps to evaluate and screen applicants on behalf of employers. This service in its own right is enormously helpful for employers. Selected apprentices are then trained jointly at the AMRC and employer’s premises and should achieve the EAL level 3 extended diploma and BTEC level 3 diploma in engineering within 3 years.  EAL is part of Semta – the Science, Engineering, Manufacturing and Technologies Alliance – which is a not-for-profit organisation responsible for engineering skills for the future of the UK’s most advanced sectors.

AMRC Apprentices are now able to progress to University of Sheffield foundation degree level within a further 2 4 months and achieve the University’s Bachelor of Science in Engineering within a further 20 months. Hallam has three apprentices in training at the AMRC currently, one of whom is now progressing to full degree level.

Two of the three were nominated for the AMRC’s “Apprentice of the Year” awards in 2017 and 2018, competing against apprentices from Rolls Royce and Siemens, and one was successful in achieving an award.

Hallam intends to continue to train all its employees at the AMRC as the basis of its skills updating and succession planning and is currently recruiting a further two apprentices for the March 2019 intake.

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Employee Health and Wellbeing: a key factor in increasing productivity

In Spring this year W Hallam was invited to take part in an Engineering Employers Federation (EEF) survey organised by the Institute of Employment Studies to investigate the extent to which investment in health and wellbeing good practice improves productivity and profitability.

This study provides clear evidence to encourage manufacturers to develop their health and wellbeing strategies. Dame Judith Hackitt DBE, EEF Chair, concluded that:-

“The report brings together existing research into health and wellbeing, insights into productivity in manufacturing and survey data from manufacturers. The findings present a compelling case that not only does employee wellbeing affect productivity in several ways, but also that it can be the crucial ingredient which helps a range of so-called ‘high-performance’ and ‘high-efficiency’ working practices in manufacturing (e.g. lean systems) to have real and sustained traction over productivity growth.”

The report refers to international studies identifying productivity gains of more than 15%  where health and wellbeing interventions are introduced into the manufacturing workplace. Interestingly these studies also show that initiatives such as lean, six sigma and total quality management are much more sustainably effective where wellbeing policies are also implemented.

In relation to mental health, the survey reveals that although current practice in the sector exhibits an “enthusiasm for conducting risk assessments of physical hazards” very few respondents carried out stress or psychological risk audits or surveys. However studies in Japan and America identify significantly lower productivity (between 13 and 17% lower) associated with employees with psychological problems.

The report defines employee “health and well being” as follows:

“Employee health and wellbeing relates to those aspects of an employee’s physical, emotional and mental health – whether determined by work or non-work factors – which have an effect on their satisfaction, engagement, attendance and performance at work”

Any policy framework should address job design, employee involvement and employee engagement, and the employer should introduce engagement surveys, stress and psychological risk assessments and detailed scrutiny of sickness absence and patterns.

In terms of specific interventions, Public Health England, in conjunction with Business in the Community, provides a series of downloadable toolkits for employers to apply in specific areas of potential disruption to wellbeing including drug and alcohol addiction, domestic abuse, mental health, musculoskeletal health, suicide risk, crisis management, physical activity, sleep and recovery after illness.

For its part, W Hallam undertakes regular employee screening over and above those statutorily required and including the free NHS blood pressure, cholesterol level and and BMI checks for the over 40s. We find that these measures are a crucial element in enhancing employee engagement and lead to more openness and sharing, which can then be extended to all aspects of the company’s operations

Rob Pickersgill, MD, W Hallam Castings Ltd, South Yorkshire, England.

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Aluminium Alloys For High Strength Pressure Diecast Components

It’s probably not generally appreciated in the manufacturing world that cast aluminium components can be made with enhanced mechanical properties relatively inexpensively by the selection of an alloy appropriate for the purpose required.

Over 200 different casting alloys are currently registered with the American Aluminium Association and additional alloys have been developed in Europe by recycler/smelters such as Rheinfelden in South West Germany. Castings made from Rheinfelden’s Magsimil-59 for example have ductility and tensile and yield strengths similar to components made from 6061 series extrusion alloys. Such components would have been expensively machined from 6061 in solid form, and the cost savings achievable by casting are clearly substantial.

These effects are achieved through the addition of alloying elements during ingot production by recyclers for the foundries. For example, modification of aluminium-silicon eutectic alloys by inert strontium improves the tensile properties of the alloys. The introduction of strontium leads to additional refinement of the structure and increases the tensile strength and elongation at break.

The addition of magnesium increases solution strengthening and allows further improvement through strain hardening while not appreciably reducing ductility or corrosion resistance.  Magnesium actually improves the ductility of aluminium alloys containing iron and silicon due to modification of Al5FeSi intermetallic inclusions from platelet to cubic form Al15(MnFe)3Si2.  Magnesium also improves low cycle fatigue resistance and increases corrosion resistance.

Silicon improves the castability of aluminum alloys due to better fluidity and lower shrinkage and increases the strength of the alloys. Silicon also Improves resistance to abrasive wear. Copper increases tensile strength, fatigue strength and hardness due to the effect of solid solution hardening, although ductility is reduced.

Hybrid aluminium/zinc alloys have been available for many years to provide exceptional mechanical properties in pressure castings. These alloys are much denser than traditional aluminium alloys but this may not be significant for smaller castings.

Not only can pressure casting replace expensive and time consuming machining or fabrication processes but such alloys can remove the need for processing after casting (e.g. heat treatment) to achieve the mechanical properties required.

Many modern foundries are “switched on” to these possibilities nowadays and designers should be encouraged to contact the foundry to discuss requirements with foundry engineers. For any particular application prototypes can always be machined from cast billet made from the special alloy proposed by the foundry, and stress testing will give a close indication of the mechanical properties which will be achieved in the cast component.

Rob Pickersgill, MD, W Hallam Castings Ltd, South Yorkshire, England.

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Frech DAK 350 for Hallam

In July Hallam took delivery of a second Frech DAK 350 cold chamber diecasting machine to increase the company’ mid-range casting capacity. Hallam now has four Frech cold chamber machines, all with online diagnostic links to Germany. In total the company runs 10 diecasting machines.

The new machine will run alongside Hallam’s existing DAK 350 to provide capacity and contingency. Hallam is also purchasing a second DMG Mori vertical machining centre to create additional machining capacity following the acquisition of the DAK 350.

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Hallam apprentice nominated for AMRC’s Apprentice of the Year awards

For the second successive year a Hallam apprentice has been nominated by staff at the Advanced Manufacturing Research Centre for an award at the Apprentice of the Year ceremony held at the University of Sheffield in May each year. Tom Vause, a second year apprentice based in Hallam’s CNC machining section, was one of three nominees in the “Academic Achiever of the Year” category. Awards were presented by Harry Gration, the well known TV news personality.

Last year Hallam’s Adrian Salatowski won the award for his category, an achievement that Tom didn’t quite manage to emulate. Nevertheless in a cohort of over 150 engineering apprentices, making the last three reflects outstanding ability and effort. Well done Tom!

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Hallam to Build New Leading-Edge Factory Unit

Hallam MD Rob Pickersgill is discussing plans to construct a new state-of-the-art 5,000 square feet factory unit on a “green field” section of Hallam’s 2.2 acre industrial site with Doncaster MBC.

The project depends partly on the completion of supply contract agreements with a highly prestigious UK OEM and also with a large European Manufacturer.

The new factory would be capable of operating to automotive, aerospace and even medical equipment quality standards, and is being enthusiastically supported from all sides’ said Rob.

Hallam has the ISO 9001:2015 standard (BSI) at present and the factory would have machinery utilising the very latest robotic technologies operated by staff trained at the Advanced Manufacturing Research Centre in Sheffield. Hallam has five apprentices training at the AMRC at present.

Low cost labour countries are still a major threat to UK manufacturers. Installation of the latest manufacturing technologies and staying up-to-date is the only sustainable defence. Hallam staff are familiar with the “Factory of the Future” at the AMRC site, which provides the vision for this development’ added Rob.

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DMG MORI delivers both toolmaking and production machining with the CMX 800 V

Hallam’s foundry is at the core of its business, producing around 20,000 aluminium castings per week from 10 die casting machines. Established in 1968 it now produces parts for a wide range of applications including industrial and domestic air conditioning systems, office furniture, DIY equipment, lighting and computer products. As part of its service, the company carries out powder coating and assembly operations to deliver a finished product to its customers. Hallam has considerable skill in die casting technology and uses this in the development of products and processes to produce prototypes and ensure their manufacturability.

To expand its capabilities the company was looking for a machining centre which could be used for extra operations on die cast parts, such as drilling and threading, and which would also be capable of manufacturing die casting tools. Colin Woodruff, Operations Manager at Hallam says, “We chose the DMG MORI CMX 800 V with 4th axis unit as it had the flexibility to finish machine castings and cut mould tools. We looked at machines which would have been a little faster for secondary machining operations on the die cast parts, but they did not have the power and rigidity necessary to cut core and cavity features in H13 tool steel. During a demonstration the DMG MORI machine achieved very high metal removal rates as well as very fast rapid traverse speeds, making it ideal for our application.  Additionally, DMG MORI has a good reputation for build quality and reliability.”

Previously, Hallam subcontracted its tooling and historically the lead times were around 6-8 weeks. Now, with the CMX 800 V, including heat treatment, tools can be completed in-house within around 2 weeks and at significantly lower cost. Colin Woodruff adds, “We are adapting to a changing industry where batch sizes are smaller. The CMX 800 V is opening up new possibilities and markets as it enables us to be competitive through lower tooling costs together with the flexibility of making much smaller batch sizes from 10 up to 400.” The technology in the machine gives some further advantages in toolmaking. Holes and NPT threads can be produced with circular interpolation making them far more accurate and, with NPT threads, deliver naturally leak proof connections for tool cooling.

Hallam uses its SolidWorks and CAMWorks CAD/CAM systems to work closely with its clients, considering details such as shrinkage, undercuts, venting and draft angles to ensure parts can be manufactured while, at the same time, producing prototypes, designing the tool and producing CNC programs for the CMX 800 V. The system is also used to design and manufacture fixtures to hold multiple parts on the machine’s 4th axis. Colin Woodruff says, “As well as tool manufacture, we need to finish machine features on the castings we produce. The trunnion arrangement we have on the 4th axis enables us to load multiple parts within the 800mm capacity of the machine. Typically cycle times are around 9 minutes and we can change the fixtures to a new part in under 20 minutes. We run the machine 24 hours per day and it is slowly taking over from the traditional methods of finishing parts.” The speed of the machine enables the finishing of around 550 sets of parts in one week which would have previously taken 1-2 months. Colin Woodruff continues, “It can take up to 13 different processes to finish a casting such as drilling, tapping, milling, fitting Helicoils and powder coating. With the DMG MORI machine most of these processes can be done in one operation, eliminating errors, reducing handling and labour content and dramatically shortening lead times.”

Workforce development is important to Hallam and the new DMG MORI machine has made a valuable contribution in this area. The company has four apprentices studying at the Advanced Manufacturing Research Centre (AMRC), where DMG MORI is a Tier 1 member, including Adrian Salatowski who won a Special Recognition Award at the AMRC Apprentice of the Year Awards 2017. Colin Woodruff says, “The apprentices love the new machine and equipment we have invested in. It has engendered a positive attitude amongst our employees and the new technology we are deploying will enable us to attract even more highly skilled and motivated people, when they see the confidence we have in our company’s future.

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