Automotive engineering specialist Ricardo UK has recently invested in two new advanced CNC machine tools from GF AgieCharmilles.

The two machines, a Mikron HSM 600U ProdMod 5-axis machining centre and a FI 440CC wire EDM machine with CleanCut generator, have been installed at Ricardo’s Midland Technical Centre facility in Leamington Spa, and are being used to manufacture a range of high precision, complex automotive and motorsport transmission and driveline components.

Ricardo’s motorsport credentials are impressive. The company has a long tradition of working in the sector, and is, quite literally one of the driving forces behind many leading edge and high profile motorsport transmission/driveline design and developments.

This reputation for technical excellence, innovation and quality has seen Ricardo become a technical partner to many of the world’s motorsport OEMs and Tier 1 suppliers. These include Ford and Mitsubishi WRC teams, Peugeot and Audi Le Mans teams and a number of F1 racing teams.

Ricardo is responsible for the design and development of the innovative seven speed dual clutch transmission system of the Bugatti Veyron – the 16 cylinder, four wheel drive, super sports car that accelerates 0-100km/h in just 2.5 seconds, and has a top speed of 400km/h.

As manufacturing engineer Pieter Roos explains, the company’s decision to invest in the HSM 600U ProdMod was as a direct consequence of winning the contract to manufacture the Bugatti Veyron’s gearbox.

“Due to the complexity of the Bugatti Veyron’s gearbox we knew from a technical, quality and commercial perspective that 5-axis machining would deliver the best results. We also recognised that 5-axis machine tool technology would be a positive addition to our manufacturing facility, and that this could also be used to machine a range of high precision, complex motorsport parts, over and above the requirement for the Bugatti Veyron project.”
He continues: “As a consequence we began searching for the optimum 5-axis machine tool solution and after evaluating a number of options from different companies, we formulated a shortlist which included the Mikron HSM 600U ProdMod.”

The machining trials set by Ricardo were designed to test the true machining capabilities of the candidates but the most important factors were accuracy and repeatability plus the potential to automate processes to enhance productivity and manufacturing flexibility.

‘The HSM 600U ProdMod with its high speed, high torque spindle technology (32kW/36,000rpm/20Nm), integrated seven station workpiece pallet changer and large capacity 220 position tool changer provided us with the best immediate and long-term solution,” Mr Roos reveals. “We have an excellent working relationship with GF AgieCharmilles and as a technical partner work closely with the company to further develop and refine our manufacturing processes.”

The second machine purchased from GF AgieCharmilles is the FI 440CC wire EDM machine – selected to enhance both capability and capacity.

The machine operates 24/7 and is being used to manufacture a range of complex motorsport parts such as splines and gears from a variety of materials that include carburised steel, aluminium, titanium and Inconel.
Because the machine is equipped with a CleanCut generator which does not leave a re-cast layer on machined parts, the FI 440CC is also being used to machine specific aerospace components manufactured at Ricardo’s HPTP facility.

GF AgieCharmilles
www.gfac.com/uk