The University of Wolverhampton’s National Foundry Training Centre (NFTC), has partnered with Ifor Williams Trailers to resolve machining inconsistencies through their ‘business assist’ program. This collaboration highlights how universities and industry leaders can work together to improve manufacturing efficiency and quality.
Addressing Machining Challenges with Castings
Ifor Williams Trailers approached the NFTC to investigate an issue they were experiencing with cast hub parts, where there was a noticeable variation in machinability between batches. Some of the castings performed well during machining, while others led to unpredictable tool wear and reduced tool life, causing disruptions in the manufacturing process. As part of the University’s free 12-hour business assist support program, the NFTC undertook an investigation to identify the root cause of the variation.
Colin Whorton, Foundry Manager at ECMS, explained, “We received samples of both good and poor machinability castings and sectioned them into small test pieces. These pieces were processed in our Metallurgy Lab at Springfield, where we performed chemical analysis, hardness tests, and microstructure analysis.”
The results of the investigation revealed significant differences in the microstructures of the castings. The good machinability castings had a homogenous microstructure with proper graphite growth and sufficient inoculation. In contrast, the castings with poor machinability were under-inoculated, undercooled, and showed non-homogeneous structures. The root cause was traced back to the inoculation process at the tier two supplier’s foundry.
A Collaborative Effort to Enhance Manufacturing
Andrew Cooper, Group Manufacturing Engineering Manager at Ifor Williams Trailers, expressed the importance of the NFTC’s findings. “The NFTC was invaluable in helping us identify the technical root cause of the variation between batches of material, as well as variations within the same batch. This knowledge allowed us to take corrective actions with our supplier, improving our overall machining process.”
This collaboration not only resolved the company’s immediate machining challenges but also provided valuable insights for future operations, helping Ifor Williams Trailers improve manufacturing efficiency and reduce waste.
Supporting SMEs Through the ECMS ‘Business Assist’ Program
The ECMS Project, led by the University of Wolverhampton, focuses on supporting small to medium-sized enterprises (SMEs) in the high-value manufacturing (HVM) sector. However, this support has since been extended to SMEs across various industries in the UK. The ‘business assist’ program offers tailored, employer-led training and technical support designed to improve productivity and foster growth in SMEs.
By providing expert analysis and practical solutions, the NFTC and ECMS continue to play a critical role in strengthening the manufacturing capabilities of UK-based SMEs, enabling them to tackle complex challenges and maintain competitiveness in a rapidly evolving industrial landscape.
Source: expressandstar.com