News: Ceramic tools that can keep cool

Machining specialists at the Nuclear AMRC in Rotherham are investigating the use of ceramic cutting tools with high-pressure coolant, a combination which could deliver significant improvements in production efficiency.

Based on the Advanced Manufacturing Park, The £25m Nuclear AMRC is a joint initiative with industry, The University of Sheffield and The University of Manchester's Dalton Nuclear Institute, and is designed to help build and enhance the UK's civil nuclear new build industry.

The Nuclear AMRC is the focal point for the civil nuclear manufacturing industry in the UK. Part of the government's High Value Manufacturing Catapult, the centre helps to develop capability and competitiveness in the nuclear supply chain through process manufacturing innovation and R&D, driving up quality and reducing cost.

The Nuclear AMRC is working with cutting tool specialist and tier one member Sandvik Coromant to test the type of tooling that uses ceramic inserts in industries such as aerospace. With excellent wear resistance at high cutting speeds on hard-to-machine heat-resistant alloys, they are often used without any coolant, to maintain the localised heat required to cut alloys such as Inconel.

Coolant can still bring benefits to ceramic machining by increasing tool life, but its delivery has to be carefully managed to avoid fracturing caused by thermal shock.

The project is focusing on Inconel, a nickel-based heat-resistant alloy widely used in reactor components and jet turbines. Initial trials on the Nuclear AMRC's Hermle C60 mill-turn centre have shown that the concept of combining ceramic inserts with high-pressure coolant is sound, delivering a significant increase in metal removal rate.

The ongoing project will aim to define optimal cutting conditions for a range of materials and applications, and to build a business case to show the cost and time advantages of the technique.

Eva McLeod, project engineer at the Nuclear AMRC, said: "Inconel's superior yield and tensile strength make it extremely difficult to machine effectively. This research will expand our knowledge of new machining techniques, develop effective methods of machining difficult materials, and help us understand more about the benefits of using ceramic inserts such as improved surface quality and reduced machining time."

Steve Weston, advanced machining application centre manager for Sandvik Coromant, added: "Working in partnership with the Nuclear AMRC provides a perfect collaborative environment to identify, design, test and deliver a fully optimised component solution."

Nuclear AMRC website
Sandvik Coromant website

Images: Nuclear AMRC

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News: AMRC testing tools that see all

Experts at the University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing in Rotherham are being called upon to test a world-leading new generation of "Smart Tools."

Sandvik Teeness AS is adding sensor technology to its tools that are used to produce complex metal components.

The Norwegian firm is already causing a stir with its Silent Tools which use special damping technology to reduce bending and vibrations in the metre long tools that are needed to machine deep holes in components for the aerospace and oil & gas industries.

Based on the Advanced Manufacturing Park (AMP) in Rotherham, the AMRC is a world-class centre for innovative research and focuses on advanced machining and materials research. Work is nearly complete on expanding its Design Prototype & Test Centre.

The AMRC's expertise is being called upon by Norway's SINTEF, the largest independent research organisation in Scandinavia, whose researchers are now producing a compact and robust sensor package to be fitted to the tip of the Sandvik Teeness tool. When the tool is machining material, the sensors will be capable of measuring temperature, vibration, position and flexing during boring.

The tools are fitted inside multitask machining units which can turn blanks into part of the landing gear for an Airbus 380, an oil valve from a "Christmas tree" or a part used in the mechanical industry.

An industry first, the collaborative project aims to improve accuracy, prevent faults arising and avoid wasted material.

Terje Mugaas, a researcher at SINTEF (pictured above, left), said: "We want to ensure that continuous feedback is provided throughout the machining process. This enables us to avoid throwing away blanks with minor flaws in material or machining. This is important because creating the blanks involves a lot of work and often expensive materials.

"When imperfections are discovered in a component today, the process is stopped and the component is normally discarded. However, with the new information the operator can interrupt the process at an early stage and correct the data to obtain the right result."

The new tool will be tested at The AMRC, which counts project partners, Sandvik and Mori Seki as members. Tormod Jensen of Sandvik Teeness (pictured above, right), explained: "This will ensure that our tool is tested in the correct processes and in materials used in this industry. It will also ensure that the tool has the required characteristics."

SINTEF website
AMRC website

Images: SINTEF

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News: Rotherham apprentice recognised for his skills

Rotherham apprentice, Jake Matthewman, has been named as a runner-up at the National Craft Skills Awards presented by Semta, the sector skills council for science, engineering and manufacturing technologies.

The award, sponsored by the Worshipful Company of Tin Plate Workers association, City of London, includes a £100 voucher as reward for his performance.

Jake is undertaking his advanced apprenticeship in mechanical manufacturing and engineering in Sheffield at Sandvik Coromant, the market leader in the manufacture and supply of cemented carbide cutting tools.

He is also completing a Level 3 BTEC Diploma in Manufacturing Engineering from Rotherham College of Arts and Technology (RCAT).

Joe Hargreaves, Jake's training coordinator from the Semta Apprenticeship Service, said: "Jake Matthewman was among the highest level of entrants for this year's craft skills award. He was chosen as runner-up for demonstrating a consistently high performance level and excellent achievements in his practical and academic work.

"For the last 10 years, the Semta Apprenticeship Service has offered apprenticeships for the metals and manufacturing sector with consistently high completion rate. We are always very pleased to see enthusiastic, dedicated talent in the engineering and manufacturing industry and congratulate Jake with his achievements; we look forward to working with new apprentices like Jake in the years to come."

Robert Bloomfield, senior manager HR of Sandvik Coromant, added: "Jake is part of our apprentice training programme in Sheffield and will progress to become a qualified engineer in our R&D facility.

"It is always very encouraging to see our Apprentices recognised for their hard work. We consider ourselves to be very fortunate to have three very capable engineering apprentices as that resource will equip us with valuable skills in the future."

Sandvik Coromant website

RCAT website

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News: Orchid acquire Sandvik's Rotherham facility

American contract medical design and manufacturing firm, Orchid, has taken over the state-of-the-art Sandvik European Centre of Excellence (SECoE) in Rotherham.

Orchid Orthopedic Solutions is a worldwide leader in the contract design and manufacture of implants, instruments and innovative technologies for the orthopedic, dental and cardiovascular markets.

A transaction with Sandvik was completed last month to acquire Sandvik Medical Solutions (SMS), a major contract manufacturer of medical implants and instruments for the orthopedic and dental markets.

The deal includes the Swedish firm's 112,500 sq ft facility at Beighton Link Business Park in Rotherham. The £4m centre opened in 2010 and brought together all the finish processing and supply management activities for the production of medical products from Sandvik's Sheffield facilities.

It has an area dedicated to rapid production and prototyping for the development and manufacture of orthopedic implants, instruments and medical material.

Part of Sandvik Venture, SMS had sales of 90 million USD in 2011 and comprised production units in US and UK with about 550 employees.

Anders Thelin, president of Sandvik Venture, said: "The divestment of Sandvik Medical Solutions is in line with our strategy to exit operations outside of the defined core businesses. There is a strong industrial logic in combining Orchid and Sandvik Medical Solutions and we are convinced that Sandvik Medical Solutions will have a positive development with its new owners."

Based in Holt, Michigan, Orchid provides innovative design and development, implant and instrument manufacturing, advanced machining, plastics technology, implant coatings and surface treatment, and packaging services.

The deal is expected to strengthen its significant influence in product offerings and customer service and create an operation responsible for approaching 30% of the world's orthopedic implants.

Mike Miller, CEO of Orchid, said: "Orchid is very pleased to have SMS and its employees join the Orchid team. Sandvik brings a global footprint and a high value expertise in casting, forging and machining of implants, and complex instruments to Orchid, allowing us to better serve our customers in the U.S., Europe, and Asia."

Altor, a private equity fund, acquired Orchid in 2011. Claes Ekström, board member in Orchid and partner at Altor Equity Partners AB, said: "The combination of Orchid and SMS will have a unique offering to its customers and become the leading orthopedic implant supplier globally. The acquisition also demonstrates Orchid's commitment to build a leader in a consolidating industry."

Orchid Orthopedic Solutions website

Sandvik website

Images: Sandvik

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News: Sandvik celebrates 150 years

Sandvik, the Swedish high-technology engineering group with sites in Rotherham has celebrated 150 years in business.

The company was founded on January 31, 1862 in Sandviken, Sweden by Göran Fredrik Göransson, who was first in the world to succeed in using the Bessemer method for steel production on an industrial scale.

This was Sandvik's first link to South Yorkshire as it was in Sheffield that Henry Bessemer established his own steelworks using his own steel making process.

Sandvik quickly became one of the world's leaders in its industry. The group currently has 50,000 employees with operations in 130 countries and annual sales of approximately SEK 83 billion (£7.7 billion).

In addition to organic growth, Sandvik's expansion has also involved a series of company acquisitions over the years.

A spokesperson for the company said: "Sandvik has successfully operated and evolved by continuously being innovative and identifying new opportunities in the markets and through various shifts in technology.

"With the talent, experience and commitment of 50,000 employees across the globe, we now cast our gaze to the future and continue our journey."

Rotherham is home to the global headquarters of Dormer Tools. The firm is part of the Sandvik Group and has developed from a traditional cutting tool manufacturer to one of the world's largest producers of solid carbide and high speed steel cutting tools. Their tools are used in cutting edge industries including the tooling designed specifically for cutting composite material in the aerospace sector.

Opened in 2009, the purpose-built facility on the Advanced Manufacturing Park incorporates a state-of-the-art training suite and a major research and development facility - one of only four such facilities worldwide.

Rotherham is also home to the state-of-the-art Sandvik European Centre of Excellence (SECoE).

The 112,500 sq ft facility at Beighton Link Business Park became fully operational in early 2010. The £4m centre has brought together all the finish processing and supply management activities for the production of medical products from Sandvik's Sheffield facilities.

It has an area dedicated to rapid production and prototyping for the development and manufacture of orthopedic implants, instruments and medical material.

Sandvik website

Images: Sandvik

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News: New members boost research capabilities at Nuclear AMRC

Another 13 companies, including worldleading equipment and material suppliers, have been accepted as full members of the Nuclear AMRC in Rotherham.

The new members will help ensure that the centre on the Advanced Manufacturing Park can apply the latest manufacturing technologies to support the UK's nuclear supply chain.

The £25m Nuclear AMRC is a joint initiative between the University of Sheffield, The University of Manchester, and a consortium of industry partners.

Member companies benefit from access to world-class R&D capabilities, participation in generic R&D programmes, access to training programmes, networking opportunities with companies along the manufacturing supply chain and industry recognition through association with a world-class centre of excellence.

Firms joining as Tier One members include two of the world's leading developers of innovative machining centres, Mori Seiki and StarragHeckert, who are providing their latest centres to the Nuclear AMRC. Further machining capability comes from cutting tool specialist Sandvik.

ITW Welding Products will meanwhile support the Nuclear AMRC's joining and cladding research. Carpenter, a supplier of specialist metal powders and materials, and manufacturing software specialist Dassault Systèmes has also signed up.

The centre's capabilities are further expanded by the new Tier Two members, who work in a range of specialist areas. Machining and materials research will be supported by the experience and resources of Houghton in specialist machining fluids, Johnson & Allen in innovative non-destructive testing, Nikken in precision tooling and workholding, Nikon Metrology in measurement and robotics, and Wheelabrator in surface preparation technologies.

Newburgh Engineering, a manufacturer of large engineered parts and assemblies, and Serco Technical Consulting Services are also joining as a Tier Two members.

Professor Keith Ridgway, programme director of the Nuclear AMRC, said: "We're delighted to welcome these world-leading companies into the Nuclear AMRC. By contributing equipment, materials and expertise, they increase the value of the centre for all the companies we will be working with. And in return, we will help them develop their own capabilities to meet the requirements of the industry leaders and seize the opportunities of nuclear new-build."

A number of the new members already have a base in Rotherham - Newburgh Engineering, Mori Seiki, Sandvik and Nikken.

A lead industrial partner in the Nuclear AMRC is Rolls-Royce, who submitted outline plans for a 21,000 sq m "Project PoWeR" facility on the Advanced Manufacturing Park in Rotherham that will see them manufacture and assemble power vessels for the next generation of nuclear power stations in the UK.

Nuclear AMRC website

Images: namrc.co.uk

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News: Royal opening for Sandvik European Centre of Excellence in Rotherham

HRH The Countess of Wessex has officially opened the state-of-the-art Sandvik European Centre of Excellence (SECoE) in Rotherham.

The Swedish firm's 112,500 sq ft facility at Beighton Link Business Park became fully operational in early 2010 and was officially opened last week.

The £4m centre has brought together all the finish processing and supply management activities for the production of medical products from Sandvik's Sheffield facilities.

It has an area dedicated to rapid production and prototyping for the development and manufacture of orthopedic implants, instruments and medical material.

Arnfinn Fredricksson, head of the medical product area at Sandvik, said: "We are delighted that Her Royal Highness has done us the honour of formally opening our new facility.

"Each of the employees has worked incredibly hard to transition this new site, while maintaining continuity of supply in a period of increasing demand, and we are extremely grateful for their efforts.

"This region is ideal because it has an established medical engineering community, excellent support from local agencies and access to talented engineering graduates through the local colleges and universities.

"It is our aim to become the employer of choice for the brightest individuals in the area, who have a real thirst to further themselves and help keep us at the forefront of our industry."

Matrix @ Dinnington, RiDO's £3.4m business centre in Rotherham, was also officially opened by HRH The Countess of Wessex during her visit.

Sandvik website

Images: Sandvik

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News: Rotherham businesses to receive Royal visits

Key developments and businesses in Rotherham are set to host a number of Royal engagements over the coming months.

Later this month, HRH The Countess of Wessex will officially open the Matrix Business Centre in Dinnington.

Developed and operated by RiDO since 2009, Matrix @ Dinnington is the fourth of Rotherham Borough Council's centres aimed at encouraging and supporting entrepreneurs.

The £3.4m centre on Dinnington Business Park provides 41 high quality office and workshop facilities and occupiers include Castus web design and data analysts Applied Cytometry.

The Countess of Wessex is also set to visit Sandvik's £4m European Centre of Excellence (SECoE) at Beighton Link Business Park in Rotherham.

Home to around 350 staff, the state-of-the-art 112,500 sq ft facility brings together all the finish processing and supply management activities for the production of orthopaedic implants and instruments. The Rotherham facility has an area dedicated to rapid production and prototyping where Sandvik works directly with the manufacturer's CAD (computer aided design) drawing to find the most suitable rapid prototyping technique.

In June, The Earl of Wessex is set to visit JELD-WEN UK Limited in Woodhouse Mill, on the Rotherham side of the border with Sheffield. The door manufacturer celebrated their 50th anniversary last year and recently completed an extension to their factory that created 30 new jobs.

In July, The Duke of Kent is set to visit the new headquarters for the MTL Group in Brinsworth. MTL Group is a fast growing contract manufacturing company that employs 310 people. It works with a global blue-chip customer base in the defence, construction equipment, rail and off-shore wind energy sectors.

The group has invested in the latest technology for the 300,000 sq ft plant, which boasts the largest laser in the UK and a 640-tonne robotic press, which is the biggest of its kind anywhere in the world.

The Duke of Kent is also set to visit Sterecycle in Templeborough, the world's first commercial scale autoclave waste treatment facility that has recently recommenced operation after a fatal incident in January.

Sterecycle is a clean technology company that uses a patented steam processing method called autoclaving to "pressure cook" household and commercial black-bag waste.

Rotherham Investment & Development Office
Sandvik website
MTL Group website
Sterecycle website

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News: Advances in machining

AEM Yorkshire are hosting an event this month that will bring together some of the leading exponents in the field of machining in the advanced engineering and materials sector.

The AEM Yorkshire Network was established in January 2010 and is run by NAMTEC (National Metals Technology Centre) in Rotherham. The network is a membership body that is aimed at companies and agencies involved in research and development and provides access to well researched information and insights into emerging technologies and markets.

The event includes representatives from leading organisations such as BAE Systems, Messier Dowty and Rolls Royce discussing their activities and view of future machining technologies, and from leading machine and machine tools suppliers such as Mazak, Dormer Tools and Sandvik Coromant.

Representatives from the University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing in Rotherham will discuss the latest technical development and the assistance they can offer and representatives from the University of Huddersfield's Centre for Precision Technologies will cover the latest advances in machining accuracy and measurement.

The event takes place on January 27 at Mid Yorkshire Golf Club, Pontefract.

AEM Yorkshire website

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News: Sandvik invests in rapid capabilities at Rotherham facility

Recognising the importance of innovation and speed to market as key differentiators for medical device manufacturers, Sandvik has invested in their rapid prototyping and rapid production capabilities at the Sandvik European Centre of Excellence (SECoE) at Beighton Link Business Park in Rotherham.

Sandvik provides a comprehensive range of capabilities, making it possible for original equipment manufacturer (OEMs) to explore designs and trial prototypes quickly and easily as well as manufacture small numbers of specialised or specific products in a short timeframe.

The Rotherham facility has an area dedicated to rapid production and prototyping for the development and manufacture of orthopedic implants, instruments and medical material. It now includes a recently acquired DMLS (direct metal laser sintering) machine, a Thermojet wax printer and an Objet resin printer.

John Reynolds special projects manager at Sandvik said: "Prototyping is an important stage in the creation of a new device, since it provides the opportunity to explore the design and make the necessary adjustments prior to full production.

"Many medical device OEMs may also require very small production runs; this may be because only ten or 20 units of particular large, high value implants are required in a year or development parts are required for inspection and analysis.

"To be competitive and succeed in the long term OEMs need to work with organisations with the experience, skills and capability to support these requirements; our program of investment coupled with our commitment to always deliver tangible commercial benefits to medical device OEMs means we are positioned to support their requests."

In each rapid prototyping project, Sandvik works directly with the OEM's CAD (computer aided design) drawing to find the most suitable rapid prototyping technique.

Using the Thermojet wax printer saves a valuable 17% of the time taken by traditional methods of prototype manufacture. The printer creates a wax pattern for analysis from which cast parts can be manufactured.

The Objet resin printer produces three dimensional patterns and models in polymer materials from layers as small as 16 microns. Production of cast samples takes just 65% of the time taken using traditional methods and the speed of tool production is particularly impressive, taking just 20% of the time of standard methods.

Sandvik is also leveraging its long experience within powder metallurgy to exploit the powder-based technique used by the DMLS machine to manufacture to almost any design.

John added: "We can also now manufacture almost any design the OEM can create, irrespective of the complexity of the geometry. This means our customers' design teams are not constrained by the manufacturing limitations previously typical in the industry. They have the flexibility to respond with precision to the individual preferences of any one surgeon or the specific needs of a patient.

"Looking ahead we will continue to develop new processes and procedures, exploiting both our long standing commitment to R&D and materials expertise, to the benefit of our customers. Indeed, Sandvik invests 3% of the Group's total sales in R&D."

Sandvik website

Images: sandvik.com

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News: JF Finnegan sells Sandvik European Centre of Excellence in Rotherham

JF Finnegan has sold the 112,500sq ft Sandvik European Centre of Excellence (SECoE) at Beighton Link Business Park in Rotherham to Cordea Savills UK Income and Growth Fund for an undisclosed sum.

JF Finnegan secured the deal to develop the facility for the Swedish global industrial group last year in what represented one of the region's largest pre-let deals.

Sandvik signed a 15 year lease to create the SECoE, for which it received a £1.7M supporting grant from Yorkshire Forward.


The facility, which became fully operational in early 2010 and has a BREEAM rating of "very good", incorporates a 90,000sq ft workshop, 22,500sq ft of office accommodation over three floors and 150 parking spaces.

The centre has brought together all the finish processing and supply management activities for the production of orthopaedic implants and instruments from Sandvik's Sheffield facilities.

Philip Ryan, Chairman of JF Finnegan, said: "The sale of Sandvik's SECoE at Beighton Link is an excellent result for the scheme and further cements the development's position as an integral contributor to South Yorkshire's long-term regeneration."

George Tindley, Fund Director for the Cordea Savills UK Income and Growth Fund, added: "Since the launch of this Fund in January 2010 we have now spent over 50% of the initial equity raised. We continue to look for well specified buildings across all sectors which offer very strong covenants and long leases."

Crossland Otter Hunt acted for JF Finnegan.

Sandvik website
JF Finnegan website

Images: corusconstruction.com

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News: Sandvik appoint LSH to monitor Rotherham investment

Lambert Smith Hampton (LSH) has been appointed by Sandvik to provide project monitoring services on the development of its new European Centre of Excellence in Rotherham.

The multimillion-pound facility at the Beighton Link Business Park will be developed by Sheffield-based firm, JF Finnegan, and will include a 90,000 sq ft workshop, 22,500 sq ft of office accommodation and 150 parking spaces.

LSH's Building Consultancy team in Sheffield will review and monitor the design and construction process, through to completion of the development, keeping a watchful eye on the progress and quality of works as well as careful cost analysis.

Barry Smith, Head of Building Consultancy at LSH's Sheffield office, said: "We are delighted to have been appointed on this prestigious scheme which will become the largest single development project in South Yorkshire so far this year.

Not only will it create many valuable jobs, providing a welcome boost to the local economy, it will also serve as a beacon of hope for the region's commercial development sector, which has all but ground to a halt in recent months owing to the downturn in the economy and lack of development finance."

Planning permission has been granted and the development will be completed towards the end of 2009.

Sandvik website
LSH websiteRotherham

Images: JF Finnegan

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News: Sandvik to create European Centre of Excellence in Rotherham

Sheffield developer JF Finnegan has secured one of the region's largest pre-let deals; Swedish global industrial group Sandvik, with a £1.7M supporting grant from Yorkshire Forward, is introducing a new state-of-the-art Sandvik European Centre of Excellence (SECoE) to be sited at JF Finnegan's Beighton Link Business Park in Rotherham.

As reported first on Rothbiz last month, Sandvik will be utilising a new 112,500 sq ft facility which incorporates a 90,000sq ft workshop, 22,500sq ft of office accommodation over 3 floors and 150 parking spaces.

Upon its completion towards the end of 2009, the Centre of Excellence will bring together all the finish processing and supply management activities for the production of orthopaedic implants and instruments from Sandvik's existing Sheffield facilities.

Sandvik will be well placed to build on its existing market leading position in the medical sector, becoming the ideal partner for medical device companies. The development will incorporate the latest in environmentally-friendly technology, minimising energy consumption and it is expected that the business will grow in the future, enabling the creation of new jobs.

David Beighton, President and Managing Director of Sandvik Medical Solutions, explained: "The new SECoE will bring together state-of-the-art technology with our commitment to skills development, faith in the Sheffield workforce and a determination to ensure excellent facilities both inside and surrounding the SECoE, making Sandvik a true employer of choice in the locality.

"The development of the new SECoE in Rotherham will complement our existing operations and create a platform for future expansion. The SECoE will provide an improved working environment and contain state-of-the-art technology and equipment. Employees will, therefore, be able to develop their skills through a comprehensive training programme and exposure to the latest technology available."

Philip Ryan, Chairman of JF Finnegan, said: "The development of Sandvik’s SECoE at Beighton Link is a major coup for both the scheme and the region and confirms our initial confidence in the development as an integral part of South Yorkshire’s regeneration."

Tim O'Connell, Business Development Manager at Rotherham Investment & Development Office, said: "We welcome the announcement of this Sandvik project. It is yet another example of how advanced manufacturing companies can thrive and expand their businesses in this region."

Sandvik website
Beighton Link website
Rotherham

Images: JF Finnegan

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News: Sandvik to make £4m investment in Rotherham

Plans have been submitted for a £4m facility in Rotherham for Swedish high-technology, engineering group, Sandvik.

The 10,451 sq m unit at the JF Finnegan development at Beighton Link includes 7,803 sq m for light industrial use, 2,090 sq m for offices and 557 sq m for storage and distribution.

The plans were submitted by Sheffield firm Hadfield, Cawkwell Davidson Ltd.

Sandvik are consolidating their existing premises spread over a number of smaller units. They have sites in Sheffield (Sandvik Medical Solutions & Sandvik Bioline) and in Doncaster (Sandvik Mining & Construction). They also own Dormer Tools, the cutting tool specialists who moved to the Advanced Manufacturing Park in Rotherham last year.

Sandvik has headquarters in Sandviken, Sweden and during 2008 the group had 50,000 employees and representation in 130 countries.

If planning permission is secured, the proposal could lead to 350 jobs on the site including 100 newly created posts.


The first phase of Beighton Link is complete and comprises of a range of industrial units from 316 sq m to 1,946 sq m. Occupiers include Viaturn, a supplier of heavy duty CNC lathes.

Sandvik website
Beighton Link website
Rotherham

Image: sandvik.com / Hadfield, Cawkwell Davidson Ltd

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