Deep hole drilling with its requirement for copious amounts of neat cutting oil can be a messy process, contributing to the negative image of engineering as a dirty business that poses a potential risk to health, safety and the environment. However, it doesn’t have to be like this, as Hone-All Precision Ltd has shown following the company’s decision to relocate its subcontract machining operations to larger refurbished premises in nearby Leighton Buzzard, Bedfordshire.
The move was prompted by the need for increased production capacity and a more efficient process flow from raw material through to finished component, along with easier access to and from the factory. However, relocation has allowed several environmental and related initiatives to be implemented as part of the refurbishment project, all of which have impacted favourably on the company as a whole.
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“While the cost of these initiatives does have a direct effect on the bottom line, it is balanced over time by a reduction in our direct costs and by less easily quantified benefits such as a better working environment,” says Andrea Rodney, Director. “Our machining capability continues to be components up to 250 mm diameter by 3 m long but doubling our floorspace to 20,000 sq. ft. has allowed additional investment in machine tools. This is a vital part of our lean manufacturing strategy, which has shortened delivery times and minimised the movement of heavy material and components through the factory. We have also reduced energy usage by installing a new roof with clear panels to let in natural light, and opting for Carbon Trust-approved, highly energy efficient daylight quality lighting throughout the factory.” |
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The expertise to produce high length-to-depth ratio holes, often in difficult to machine materials such as Inconel and Hastelloy, while guaranteeing excellent surface finish and straightness characteristics is key to Hone-All Precision’s steady progress over the past decade. In terms of deep hole drilling this equates to a surface finish of 0.8 µm/32 CLA and a total run-out (TIR) of 0.025 mm/25.4 mm. Typical components requiring deep hole drilling up to 30 mm diameter include con rods, drive shafts, steering columns, electronic housings, injection mould tools, prosthetics, rotors, actuators and landing gear. For holes with a diameter greater than 30 mm, the alternative is deep hole boring, which is the machining process used on the replica 16th century cannon featured in the Master and Commander film starring Russell Crowe. CONTINUED |
