Taking place amid a manufacturing sector remaining bullish in the face of a fresh economic crisis, Southern Manufacturing returns to FIVE, Farnborough from 15-16 February to demonstrate the best of British.

This time last year, Southern Manufacturing organiser European Trade & Events Services (ETES) was looking forward to 2011 with cautious optimism. This time around it seems the threat of financial uncertainty once again threatens to plunge the economy into crisis. UK manufacturing however seems to be painting quite a different picture and while the overall economy is expected to stumble next year, the prospects for within the sector are continue to be more optimistic.

According to the manufacturers’ organisation EEF, 90% of its members are involved in export business and for nearly half of them, exports account for the majority of their turnover. The largest export market for UK manufacturers is not Europe, but Asia and the low value of Sterling outside the EU is making UK firms not just competitive, but highly attractive once their high level of technical expertise and specialist skills is factored into the equation.

Having undergone a quiet transformation from heavy manufacturing to knowledge-based enterprise, the UKs rich ecosystem of highly specialised engineering SMEs have grown extremely adept at seeking out and exploiting opportunities at home and abroad.

It is against this backdrop that Southern Manufacturing returns, describing itself as the ‘quintessential SME event; an incredibly vibrant marketplace for products and services’. ETES believes that if exhibitor numbers are any indication of the business prospects for 2012, UK manufacturing has little to worry about. 2011 was a record year for Southern Manufacturing and 2012 looks set to be another record breaker. Exhibitor bookings passed the final total for 2011 in October and the organisers are forecasting a further 900m² of exhibition area to be snapped up ahead of the show’s opening.

The show’s continued focus on the small to medium enterprises that make up the core of UK manufacturing is a key factor in its continued success. “Smaller, highly specialised manufacturing companies seem to be thriving,” says show director Phil Valentine. “We’re seeing some really exciting things happening in advanced manufacturing, medical device technology and precision engineering.” All of these and more will be well represented at the 2012 event, with new exhibitors making up a 20% of the total.

Companies such as Amada, Haas Automation, XYZ Machine Tools, Yamazaki Mazak, Fanuc and Faro are among the familiar names returning in 2012. Joining them is an array of smaller suppliers, between them covering just about every possible requirement. Southern Manufacturing is also co-located with two other events, Southern Electronics – now the UK’s longest running electronics show – and Auto Aero, the specialist precision engineering event, popular with subcontractors.

Southern Manufacturing is also well known for its free technical seminar programme running over both days in two theatres. The 2012 programme features speakers from The Manufacturing Advisory Service, UKTI, BAE Systems, EDF Energy, NAMRC, Farnborough Aerospace Consortium, University of Sheffield and The Composite Systems Innovation Centre, amongst others.
Entry to all three shows and the seminar programmes is completely free to registered business visitors with FIVE Farnborough offering plenty of free car parking and easy access by road or public transport.

Industry showcase

So what can visitors expect to see? Precision engineering company Renishaw (stand Q48) will be exhibiting its range of additive manufacturing, metrology and encoder systems. Visitors will be introduced to its SLM systems, which utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a high powered fibre laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100µm.

Also on show will be Renishaw’s newest gauging product, Equator. Its patented low cost design is capable of high speed comparative gauging for the inspection of high volume manufactured parts. Equator is a fast and highly repeatable gauge that operators can use with push button simplicity and can switch between parts in seconds.

Also exhibited will be the PH20 5-axis touch trigger system, the new RLP40 and OLP40 lathe inspection probes, a range of encoders including the Resolute ETR (Extended Temperature Range) and the RoLin, for embedded motion control applications.

Hampshire-based ICEE Managed Services (stand K30) will demonstrate a range of waterjet cut parts giving visitors an opportunity to see firsthand the range of cutting offered by the technology. ICEE has recently invested in a Bystronic BySprint fibre laser and a new building next to its head office in Waterlooville where its waterjet, brake press and new fibre laser machines all reside.

By offering both laser and waterjet cutting, ICEE is able to supply a profile/cutting service for a wide range of materials, finishes, thicknesses and a choice of processes. The waterjet is a cold cutting process for virtually any materials up to 230mm thick, enabling cutting of materials that cannot be cut by conventional methods where heat becomes a major factor in the finished product.

The fibre laser is the best cutting solution for thinner metals between 0.5-12mm thicknesses, including traditional mild and stainless steel but also encompassing the cutting of aluminium, brass, copper and other composites. Again – there is less heat absorbed by the product when using a fibre laser compared with conventional laser cutting technologies.

Coordinate measuring machine manufacturer Aberlink Innovative Metrology (stand U7) will be bringing its Axiom Too CMM to the show. Available in manual or CNC variants, this advanced, easy to use CMM is capable of delivering consistent, precise results within an inspection department or on the shopfloor.

As with all of the company’s products, the Axiom Too utilises Aberlink’s intuitive software that ensures greater user productivity and profitability. Illustrating the global popularity of Aberlink’s software across a wide range of measuring arm and CMM brands, it will be demonstrating the software’s many advantages on a Faro Arm.

Also on display will be its Project X optical measuring device. Based on a patented, colour matrix scale, X, Y and rotational positions can be plotted with high levels of accuracy. Although Project X features a large measuring capacity of 400mm by 300mm with 125mm of motorised Z-axis focus, it retails for the same price as a conventional profile projector whilst delivering more functionality and enhanced accuracy.

Yamazaki Mazak (stand Q60) is to bring its new Integrex i-200 S to Southern Manufacturing – described as a latest generation multitasking machine ideally suited to subcontract manufacturing, providing real versatility and performance which is both environmentally friendly and energy efficient.

The new generation Integrex i-200 S is capable of completing all turning and machining operations, from raw material to finished component, in one hit, one set-up and on one machine, encompassing the company’s ‘Done-In-One’ philosophy. The main spindle is equipped with 22kW of power and a maximum rotating speed of 5,000rpm. Milling spindle power has also been increased to 22kW for a 30 minute rating and is capable of 12,000rpm.

The Integrex i-series is one of the first Ken Okuyama designed machines available in the UK and benefits from a range of ergonomic features based on customer feedback, including a larger viewing window and a 19 inch display panel on the Mazatrol Matrix control, which is also height adjustable for ease of operation.

XYZ Machine Tools (stand S60) will demonstrate that when it comes to cutting metal, especially in prototype and low volume applications, it offers a cost-effective route to increasing productivity and reducing costs. The Burlescombe, Devon company’s CNC/manual and full CNC machines – ranging from ProtoTRAK equipped CNC/manual mills and lathes to Siemens CNC equipped machining centres, turning centres and large capacity oil country lathes – are specifically designed to be easy to program and quick to set-up.

On the stand will be a 5hp variable speed (40-5,000rpm) ProtoTRAK SMX 3500 bed mill; a 7.5hp/25-2,500rpm ProTURN SLX 425 lathe; a 20hp/5,000rpm Compact Turn 52 turning centre; and a 20hp 5-8,000rpm 710 VMC. The two ProtoTRAK equipped CNC/manual machine tools feature the latest generation version of this easy to program control, while the full CNC CT 52 and 710 VMC are equipped with the new Siemens 828D conversational control.

ProtoTRAK, which is programmed via ‘plain English’ prompts, was developed by Southwestern Industries in California more than 25 years ago and is fitted exclusively to the XYZ range of CNC/manual machines. The Siemens 828D conversational control fitted as standard to XYZ full CNC machines can also be programmed on the shopfloor without any G coding knowledge, courtesy of ShopMill/ShopTurn sequence programming.

Roemheld (stand R66) will be showing off the latest additions to its zero point mounting ranges and 5-axis vices at Southern Manufacturing, where visitors can see its new, fast closing mounting system that simply clicks into place and holds immediately, making it ideal for use within an automated cell.

The Stark SPEEDY easy click is a mechanical fast closing clamp that engages without the application of any force and which holds immediately. A quick release of 0.1 seconds can be achieved through either a simple air connection at a pressure of 3-8 bar or a power socket – ideal for use in cutting and non-cutting 5-axis machining centre applications.

On display will also be a wide selection of newly launched workholding solutions, including the flagship Hilma KC100 5-axis vice. This combines all the features of the SCS vice range with the added advantage of round carbide inserts, which enable concentric components to be gripped in the same vice. The KC100 vice will be on show alongside the latest additions to the MC range of fixed jaw and concentric operated vices.

The display being mounted by Heidenhain (GB) (stand P49), the supplier of angular, linear and rotary encoders, digital readouts and CNC systems, will offer visitors representative examples of the comprehensive array of technologies offered.

These include its new Acanto absolute digital length gauge, digital readouts for retrofit applications; a TNC machine tool control programming station, complemented by spindle and table probes and providing a useful insight into Heidenhain CNC systems and ideal for training and offline programming routines; and a representative range of absolute and incremental linear and rotary encoders, embracing all types of measurement applications.

The latest Haas (stand P60) high performance turning centre will also be put through its paces at the show. The ST-30 has been designed to provide heavy cutting ability, extreme rigidity and high thermal stability. It has a maximum cutting capacity of 533mm by 660mm, with maximum swings of 806mm over the front apron and 527mm over the cross slide.

The ST Series of CNC lathes is the culmination of extensive design and real world testing aimed at making Haas lathes amongst the finest available. At present, more than 25 000 high performance Haas turning centres are installed worldwide, proving their capabilities in machine shops every day.

The ST-30 CNC lathe's standard 30hp spindle yields 275ft/lb of torque at 700rpm and spins to 3,400rpm. For heavy cutting operations, an optional two speed gearbox increases torque to 840ft/lb at 200rpm. The A2-6 spindle nose is equipped with a 10 inch hydraulic three jaw chuck and the machine is equipped with a 12 station bolt-on style tool turret. The ST-30 also comes with Y-axis and as a Super Speed version.

Haas CNC turning centres include such innovations as massive headstock castings with symmetric ribs for rigidity and stability; large tailstock castings with a two piece design for easy realignment; embedded chip trays for improved sealing and efficient chip removal; increased volume, roll-out coolant tanks; and double wall doors riding on precision bearings for smooth, reliable operation.

In previous years at Southern Manufacturing, Trumpf (stand P36) has focused on its leadership in laser technology for product marking. The 2012 event will be no exception but in addition the company will also demonstrate its precision bending capabilities with one of its TruBend machines.

The entire TruMark product range is modular. Standard modules with fundamental functions are complemented by those with special features for different tasks. This concept enables Trumpf to provide cost-efficient and service friendly markers optimally designed to suit the application and which can be upgraded at any time.

Two Trumpf TruMark laser marking machines will feature at the show. The TruMark 5020 with diode pumped fibre laser combines high power, high repetition rates and variably definable pulse duration. Also on display will be the TruMark Station 1000 desktop laser system with a TruMark 3130 marking laser.

On the bending side the company will be promoting its TruBend 7036, which with its high speed and acceleration of the beam and back gauge, is one of the world’s fastest bending machines.
WNT (UK) (stand S48) is using its presence at Southern Manufacturing to highlight the productivity gains available thanks to recent developments in solid carbide milling and indexable insert turning technology.

Two key areas have been addressed: milling of steel and cast iron and the turning of stainless steel materials. In both cases WNT has developed products that is said to significantly boost tool life and productivity to deliver major cost savings.

The range of SCR Monstermill solid carbide end mills has proved to be effective for high performance cutting applications on steel and cast iron components with hardness values up to 70 HRC. In these applications typical productivity gains are in the order of 25%. These improved performance figures are achieved due to the combination of a recently developed carbide substrate and a Ti1200-based AltiN (Aluminium Titanium Nitride) coating.

The recent launch of WNT’s HCN 2125 carbide grade for the machining of stainless steels is also solving the age old problem of poor tool life when machining stainless steel materials, and represents a grade that can increase tool life by as much as 50%, thanks to its new carbide substrate and Dragonskin PVD tool coating.

Blum-Novotest (stand S31) will give its UK debut to the new TC76-DIGILOG – claimed to be the world’s first touch probe for robust use in machine tools, combining digital and analogue technology. Alongside will also be the new Tool Monitor Adaptive Control (TMAC) tool monitoring solution which protects CNC machines while providing valuable information regarding the cutting process.

The system reduces the high cost of replacement tools, lost production and rejected parts by effectively measuring tool wear in real time. It operates on the principle that the horsepower required to cut a part increases as the condition of the cutting edges of the tool deteriorate.

These new developments will be shown alongside established and successful products like the LaserControl NT-H 3D and the Z-Probe series for tool setting and measurement. The Blum stand will also show the established TC50 workpiece touch probe and the TC52. With a diameter of 40mm and an effective length from spindle nose to stylus tip of only 112mm, the TC52 has an innovative optoelectronic measuring unit which produces the same measuring results when probing in various directions. For higher accuracy, versatility and reliability, the TC53-10 probe for tool and workpiece measurement for milling, turning or combined mill/turn machines will also make an appearance.

Precision machining subcontract specialist Rodmatic (stand S37) is to demonstrate its single source strategy capability that spans assembly to production of a diverse range of components in a wide range of materials at the exhibition.

The 30,000ft² facility in Reading houses 50 CNC sliding headstock and sliding head turn/mill centres, multi-axis fixed head turn/mill centres and 38 multi-spindle automatic lathes that together produce over 500,000 components a week. More than 90% is exported to customers in the automotive, fluid power, specialist automotive, marine and medical sectors.

Unlike many subcontract operations, Rodmatic has its own CAD/CAM and toolroom which features wire EDM installations used for special form tool manufacture and highly specialised component production for the autosport and medical sectors.

Rodmatic provides a complete service with the ability to machine small batch to continuous production as well as sourcing outside processes such as heat treatment, grinding and surface finishing. It is willing to stock parts with strict inventory control and supply standard components such as electrical or electronic items to support its assembly operations. Materials machined include mild, stainless and high alloy steels, aluminium, brass and titanium.

Inca Geometric (stand Q66) is to demonstrate its wide ranging capability in subcontract machining and project-based engineering skills. Its long-term machine tool expertise spans 50 years of design, development, build and supply of special purpose equipment, assembly and test rigs as well as made to order multi-heads for drilling, boring and threading for a wide array of international companies. These have spanned automotive, fuel injection, transmission, pump and valve, defence, leisure, and oil and gas.

Through 2011, following over £500,000 investment in new production equipment and CAD/CAM software, this has allowed further expansion of its subcontract precision machining, fabrication and assembly business.

Projects completed during 2011 include a test rig for truck braking systems, a planet hub assembly machine, the machining of defence, aerospace and valve components, the winning of an export machining contract for granite rings used in gaming equipment and the precision grinding of compressor rotors. The company has also completed a contract for the stripping out and re-engineering of mechanical handling conveyors, elevators and walkway systems for a leading automotive company.

Industrial Tooling Corp (ITC) (stand N67) will be introducing a number of new product developments at the show. Amongst its new offerings is the 5021 Cyber Series of 5 flute harmonic end mills.

For difficult to reach surfaces and cavities in hard steels and aerospace alloys, the new 5021 Cyber Series range promotes high performance levels when processing difficult materials. The solid carbide 5021 is Cupro coated to enhance tool life and machining stability. The cutters demonstrate stability and rigidity through an unequal flute spacing that reduces machining noise and vibration. The right hand cutting and right hand helix range is available in diameters from 3-32mm with radius options from 0.5-4mm dependent upon diameter.

Complementing the 5021 Series at Southern Manufacturing will be the new 6051 Cyber Series end mill range. ITC says the high performance six flute series of cutting tools has already made a significant impact on cycle times and tool life for many aerospace OEMs and F1 manufacturers. This long length, straight shank solid carbide cutter also has an unequal flute spacing and Cupro coating.

Other products on show include the 3081 Series, the new 2161 Cyber Series and 2161 Radius Series of two flute end mills and the new 2201 Cyber Series of two flute solid carbide end mills, all designed for aluminium machining.

Following a tough climb out of recession, DJJ Engineering (stand N48) found it necessary to expand its target markets. For 36 years the South Wales-based subcontractor specialised in undertaking precision machining work for the motorsport and automotive sectors – but it was time to cast a wider net.

DJJ now provides an impressive range of precision turned and milled parts to customers in a diverse spread of industries that encompasses automotive, aerospace, marine, defence, medical, and oil and gas. “We offer a complete service, operating 24/7 and supplying everything from design and prototyping expertise through to full batch production,” affirms managing director, Dennis Jones.

Aside from the recessionary impact on the business, DJJ also experienced problems recruiting people of the right calibre during the recovery. Consequently DJJ, along with Welsh Assembly Government assistance created a continuous programme of in-house engineering training which has been running successfully for almost a year.

“We turn our business into a classroom for two hours every week and all our operators undertake engineering skills and quality training programmes provided by fully qualified external expert services,” Mr Jones adds. “Training will pick up again in mid January and will include extensive on to one training from a variety of external machinery providers and will cover every piece of equipment on our premises. DJJ has also embraced the engineering apprenticeships programmes and currently employs seven new apprentices – four of whom are in full time study. We felt this was the only way to find the experience we needed – to train them ourselves.”

DJJ is well on the road to full recovery and this year has invested in new machines from Hurco and Yamazaki Mazak. “We’re really looking forward to our attendance at Southern Manufacturing 2012 where we have again designed a number of small component pieces to showcase our extensive range of services,” Mr Jones concludes.

Southern Manufacturing
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