Five-axis machining

Ricardo UK Ltd, the automotive engineering specialist, has invested in two advanced CNC machine tools from Coventry-based Agie Charmilles Ltd. These machines — a Mikron HSM 600U ProdMod five-axis machining centre and a wire-EDM machine with CleanCut generator — have been installed at its Midland Technical Centre in Leamington Spa. They are being used to make a range of high-precision transmission and drive-line components.

Ricardo is a technical partner to many of the world’s motor-sport OEMs and Tier One suppliers. It was responsible for the design and development of the ‘state of the art’ seven-speed dual-clutch transmission system of the Bugatti Veyron super sports car, which can go from 0-100km/hr in just 2.5sec.

The company’s decision to invest in the HSM 600U ProdMod resulted from the Veyron project. Manufacturing engineer Pieter Roos says: “Due to the complexity of the Veyron gearbox, we knew that five-axis machining would deliver the best results from a technical, quality and commercial perspective. We also recognised that five-axis technology would be a positive addition to our manufacturing facility, looking beyond the Veyron project.”

The HSM 600U ProdMod was chosen for a number of reasons. “It followed an extensive trial period where we invited a number of five-axis machine tool manufacturers/suppliers to help us with the project. Accuracy and repeatability were the most important factors in these trials, but we were also keen to explore the potential of automation and how it could increase our productivity and manufacturing flexibility in the future. The HSM 600U ProdMod — with its high-speed and high-torque spindle technology, integrated workpiece pallet changer and large-capacity tool changer — provided us with the best immediate and long-term solution.”