Advanced Engineering 2016 - National Exhibition Centre, 02 - 03 November 2016

The UK's largest meeting place for advanced engineering professionals

Numill Tooling Solutions

Numill Tooling Solutions

Stand J95

Contact details

S63BG Sheffield
United Kingdom
www.numill.co.uk

Numill is the leading tooling solutions company to all sectors including rail, automotive, aerospace & energy. With over 47 years of experience and expertise Numill remanufactures complex tooling to give 100% capability and an excellent value proposition for any industry. Numill is a highly motivated, quality led company serving UK industry and export clients. Come and see us on J95 to hear more.

Products

  • Ford Dagenham Engine Plant use Numill Tooling Solutions in the expert repair of their complex cutters.

    Case Study : Remanufacturing value
    Here at Numill we service many of the leading automotive groups by remanufacturing, modifying and manufacturing standard and specialist tooling. There is a continuous cycle of damaged tools sent to us for repair from all over the world which we quickly, and expertly, remanufacture to 100% working capability.
    Our clients include Renault, Mercedes, Skoda, Seat, Ford and Jaguar Landrover.
    We understand that down time in any of these plants is not an option but the specialist tooling is too expensive and time intensive to be able to replace in short enough lead times to avert production issues.
    For over 20 years Numill have been a key supplier to Ford. They had to overcome the problem of continuous damage to a set of high value whirling cutters. These complex, multifunctional cutters are used in pairs on the crankshaft production line in Dagenham Engine Plant.
    Customer Needs:-
    To keep the production line running.
    Customer Goals:-
    Reduce the costs of buying new tooling and avoid the production stoppages & down time due to long lead times.
    Investigation:-
    The process of machining metal does mean that tooling is inevitably going to get damaged in its lifetime and due to the nature of how the crankshafts are produced this does happen frequently to the whirling cutters. The biggest problem is that the cranks are originally cast which means there is an uneven amount of stock material that needs machining. This causes the cutter to work harder which in turn wears the tool out sooner than it should. The cutting parts of these tools are carbide inserts sitting in rows and have to be exactly in line with each other. The relationship between each row is vital. These inserts once worn shatter causing the damage to the cutter body (image A). As soon as even one insert has broken then the whole tool starts to underperform and lead to more inserts shattering. So the sooner any damage is spotted the better.
    Image A
    Proposal:-
    Because the casting and machining process couldn’t be changed the only option left was to look into the tool life of the cutters themselves. This led to the development of a process to remanufacture these tools at a fraction of the cost with a short delivery but without compromising quality or performance.
    Our recommendation to Ford was for all damaged cutters to be sent to us along with enough new inserts and screws to refit the entire tool. Upon receiving the cutters preparation includes removal of used and broken inserts and screws. Viable items will be re-used.
    We then carry out the remanufacturing process (image B). This is finalised by fitting the cutter with supplied inserts and screws and fully inspecting every insert position to guarantee that Ford’s own cutter grinder sections receive a cutter that they can be confident will function at 100% capability.
    They then do their own final dimension inspection before releasing it back onto the production line.
    Image B
    Conclusion:-
    After initially conceptualising the remanufacturing process and developing the necessary work holding equipment we were able to offer Ford an invaluable service which has continued for over 20 years.
    All damaged cutters are returned fully fitted and inspected within 5 to 10 days (image C & D).
    The cost savings by Ford compared to buying new ranges between 90% for a minimal damage cutter to 60% on an excessive damage cutter.
    Ford also purchased a spare set of cutters which helps create a cycle to replace the damaged ones with the spare set while the remanufacturing is carried out.
    Image C Image D
    Summary:-
    The customer’s needs and goals were totally satisfied by Ford choosing to have these expensive, complex cutters remanufactured by Numill. We have over 45 years of knowledge and expertise in the field to draw on to find solutions for our clients.
    The cost saving benefits offered by remanufacturing together with mitigation of potential losses caused by production line stoppages are significant.
    Remanufacturing saves money whilst providing the quality demanded.
    Our ‘value adding’ service is an integral part of our clients supply chain options.

  • Automotive Sector Tooling awaiting expert attention from Numill Tooling Solutions

    Numill have over 20 years experience dealing with the highly complex, expensive tooling used by the automotive industry. We offer an amazing value proposition to all industries but automotive represents some of the highest cost savings against new tooling all expertly remanufactured by our highly skilled engineers based in Sheffield, UK.

  • Rail industry cutter used for profiling rails

    Railtrack
    Numill Ltd has been serving rail industry companies for over 45 years. We provide an invaluable service to many of the leading rail groups by remanufacturing, modifying and manufacturing standard and specialist tooling. Cutting tools in this sector are usually doing heavy machining work which leads to a constant flow of damaged tools that need repairing quickly and cost affectively. The damaged tooling can come from anywhere globally and it is our aim to expertly remanufacture these tools to 100% working capability.
    Our customer list includes Progress Rail, Balfour Beatty, Cummins Engines, Wartsilla and Tata. We are also members of the Rail Alliance.
    We are fully aware of the time constraints our customers face and know that any tooling failure could result in considerable delays and cost implications due to the expense of the specialist tooling and the length of time it would take for a replacement to be made.
    For years now Numill have been helping railtrack companies avoid these lengthy delays and saved all of them money by remanufacturing their damaged tools.
    An example of our service:-
    We have customers that machine the rail track form, owls and all varieties of frogs using complex and expensive special tooling that creates the rail form as shown below.

    The machining of these track sections inevitably leads to the tools getting damaged due to the high metal removal rate that can take place because of uneven castings. The uneven amount of stock material that needs machining off the cast track sections causes the cutter to work harder which in turn wears the tool out sooner than it should. The cutting parts of these tools are carbide inserts that are positioned to accurately cut the required rail form. The relationship between each row is vital. These inserts once worn shatter causing the damage to the cutter body. The cutter pictured below was spotted early and only had 1 pocket damage.

    As soon as even one insert has broken then the whole tool starts to underperform and leads to more inserts shattering. So the sooner any damage is spotted the better.
    On the first occasion that one of these cutters was presented to us for repair we were asked to provide any ideas and information on how to stop the cutters from becoming damaged in the future.
    The casting and machining procedures of these large sections of track and junctions couldn’t be changed. That meant the focus had to be on the durability, lifespan and cost of the cutters themselves. This led to the development of a process to remanufacture these tools at a fraction of the cost with a short delivery but without compromising quality or performance.
    We recommend to anyone using these expensive special cutters to be vigilant and look for the first signs of damage. Then send them to ourselves along with all the inserts and screws to refit the entire tool. Upon receiving the cutters preparation includes removal of used and broken inserts and screws. Viable items will be re-used.
    We then carry out the remanufacturing process by using a special weld deposit that is machined and heat treated back to the tools original hardness spec. This is finalised by fitting the cutter with supplied inserts and screws and fully inspecting every insert position to guarantee that the customer can be confident the repaired tool will function at 100% capability.
    Summary:-
    After initially conceptualising the remanufacturing process and developing the necessary work holding equipment we have been able to offer all of our customers an invaluable service which has continued for over 40 years.
    The cost saving benefits offered by remanufacturing together with mitigation of potential losses caused by production line stoppages are significant. The repairs alone can save between 70% for a minimal damage cutter to 30% on an excessive damage cutter.
    Remanufacturing saves money whilst providing the quality demanded.
    Our ‘value adding’ service is an integral part of our clients supply chain options.
    The video link below shows various operations of track sections being machined. Numill can remanufacture all the tools seen in the clip. Please watch to the end to see an example of the featured tool in operation
    https://www.youtube.com/watch?v=7oisnrPYXyw

Contact Numill Tooling Solutions now!

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