Capacity and Resources - Doncasters€¦ · Boko F1 – CNC Control, Table size 1200mm x 800mm,...

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Copyright Doncasters Group 2014 Strictly Private & Confidential

Capacity and Resources

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Fabrication Press brake (CNC) – Sheet size up to 3000mm x 3000mm x 5mm thick. (2 machines)

Rolling straight and cone – Sheet size up to 3000mm x 3000mm x 5mm thick. (5 roll sets)

Electron beam welding – Chamber size 1000mm x 1000mm, up to 10mm thick material.

Auto Longitudinal TIG – Diameter 1500mm x 2000mm high. (5 machines)

Auto Circumferential TIG – Diameter 1500mm x 2000mm high. (2 machines)

Robotic 7 axis Plasma/TIG – Components up to 2m cube. Rotary manipulators for single set up circumferential and longitudinal welds.

Max weight 1000Kgs. (4 robots)

Manual TIG including sheet metal assembly and fabrication – Components up to 2m cube x 5mm thick. (12 Bays)

Resistance Seam welding – Diameter 1500 x 800 to tip. (6 machines)

Resistance Spot welding – Diameter 1500 x 700 to tip. (3 machines)

Laser cutting – 6 axis, component size 1600mm x 1600mm. (2 machines) further machine due in 2014

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Forming Pressing (hot and cold) – Table size 1200mm x 1600mm.

Hydro Bulge – Diameter 1500mm x 2000mm high, with in process de greasing. (7 chambers)

Hot Gas Bulge – Components up to diameter 1200mm x 1500mm high.

Expanders – Various fixtures, max diameter1500mm x 1500mm high. (2 sets)

Electro Forming – Components up to 1600mm x 150mm x 1000mm, typical thickness 1-2mm. (26 baths)

Stretch Forming – Components up to 3600mm long and 2500mm wide, typical sheet thickness 2mm. (3 machines)

SPF (Super Plastic Forming) – Components up to 1500mm x 2000mm. (4 Presses)

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Machining

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Turning

CNC – Diameter 540 mm x length 500 mm, 14 tool stations. (2 machines)

Manual – Diameter 800 mm x length 2500 mm. (2 machines)

Vertical Boring

Toshulin SKIQ12 – Diameter 1200mm x 1000mm under rail, 14 station tool changer, Fanuc control, Max RPM800.

Toshulin SKS12 – Diameter 1200mm x 1000mm under rail, 14 station tool changer with live tooling, Fanuc control, Max RPM800.

Toshulin SKIQ8 – Diameter 1000mm x 800mm under rail, 15 station tool changer, Fanuc control, Max RPM400.

Toshulin SKI16 – Diameter 1600mm x 1500mm under rail, 15 station tool changer with live tooling, Fanuc control, Max RPM1000.

Toshulin SKIQ12 – Diameter 1200mm x 1000mm under rail, 14 station tool changer, Fanuc control, Max RPM800.

Toshulin SKJ12 – Diameter 1200mm x 1000mm under rail, 10 station tool changer, Siemens control, Max RPM200.

Toshulin SKI12 – Diameter 1200mm x 1000mm under rail, 8 station tool changer, Fanuc control, Max RPM200.

CNC Lance – Diameter 1200mnm x 1000mm under rail, 5 double side tools, Max RPM100.

CNC Webster Bennett 48” – Diameter 1200mm x 1000mm under rail, 5 double sided tools. (2 machines)

Webster Bennett 36”, 48” and 72” – Manual, Surface and boring. (6 machines)

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Machining

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5 Axis Machining

Mazak 1060 multi tasking machine – Diameter 1200 mm vertical boring and 5 axis milling, 120 station tool changer, Twin pallet

changer, Mazatrol E tower control, High pressure coolant, Offline tool pre setter and in process Renishaw probing. (2 machines)

Mandelli – Multi pallet 5 axis milling centre, Table size 1000mm x 800mm, Max work piece 1400mm x 2000mm, max spindle speed

7000RPM, 100 station tool changer, Offline tool pre setter and in process Renishaw probing, Siemens control.

Hermle – Diameter 1000mm Trunion and rotary table, 87 station tool changer, Offline tool pre setter and in process Renishaw probing.

Milling

Boko F1 – CNC Control, Table size 1200mm x 800mm, Universal head.

Boko F63 – CNC Control, Table size 1200mm x 800mm, Universal head.

Hartford – Table size 3000mm x 1500mm, 40 station tool changer, Fanuc control, Renishaw probing.

Horizontal Boring

Cincinatti – Table size 1000mm x 1000nm, Sine Table, Heidenhain Control, 30 station tool changer.

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Processing Grit Blast – Components up to diameter 1200mm x 1200 mm high. (4 chambers)

Vapour Blast - Components up to diameter 2000mm x 1500mm high. (3 chambers)

Bead Blast – Components up to diameter 1500mm x 1200mm high.

Drying Ovens – Components up to 2000mm x 2000mm x 2000mm high. (3 chambers)

De-greasing – Components up to diameter 1500mm x 2000mm high.

Painting Bay – 3000mm x 3000mm x 2000mm high. (2 Bays)

Stoving Ovens – 1500mm x 1500mm x 2000mm high. (2 chambers)

Air Furnaces – Chamber diameter 1500mm x 2000mm high. (4 chambers)

Vacuum Furnace – Chamber diameter1500mm x 1800mm high.

X-ray – Max component size 2m cubed. (4 bays)

FPI – Max component size 2m cubed. (4 bays)

MPI – Max component size 2m cubed. (1 bay)

Semi–Automatic riveting – Diameter 1500mm x 2000mm high. (4 machines)

Chemical processing of Ti and Ni alloys, Components up to diameter 1500mm x 2000mm high. (23 Baths)

Assembly – Generic and cell dedicated, for the fitting of Heli-coil and wobble broached Inserts, Captive nuts and Shrink pins etc

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Manufacturing support Brown and Sharp, Co-ordinate Measuring Machine – 1600mm x 3000mm x 1200mm.

Part Marking – Inkjet, Data Matrix, Etching.

Faro Arm. (2 machines)

Laboratory support in 4 locations.

Tool room facilities including – Turning, Milling, Boring, Drilling and Grinding.

Drawing, Modelling and offline Programming – Auto CAD, Onovia, Catia and Unigraphics.

Fully integrated MRP system.

Qualsys EQMS system.

Consignment stocking of raw materials and standard parts.

World wide line side shipping

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Cellular Manufacture Exhausts Process Line including:-

Rolling and Pressing

Circumferential and Longitudinal automatic welding

Machining

X-ray and FPI

Hydro-Bulge

Semi-automatic riveting

Brazing

Heat Treatment

Assembly

Inspection

Packing

Track Can Process Line including:-

Machining

Fabrication and Welding

Heat Treatment

Laser cutting

Chemical Milling

X-Ray and FPI

Painting

Part Marking

Assembly

Kit Box Packing

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Location Sheffield, UK

Markets Aerospace

Processes • Hydro forming

• Super Plastic forming (SPF)

• Hot & Cold Press Forming

• Electroforming

• 6 Axis Laser cutting

• Aero Engine ring machining cell

• Specialist solid case machining cell

• Vac Heat Treat

• Ti & Nickel Chemical Milling

• Paint and Plasma

•Welding:

Electron Beam

Laser

Plasma

Robotic

Resistance

Circ & Longitudinal

•NDT/Xray

•C class part Assembly

•Semi-automatic riveting

Materials Inconel Titanium Jethete

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Sales and Commercial Contacts

Michael J Broadhurst

Lead Estimating Engineer

Doncasters Bramah

+44 114 251 2047

mbroadhurst@doncasters.com

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Paul Taylor

Estimating Engineer

Doncasters Bramah

+44 114 251 2117

ptaylor@doncasters.com

John Marsh

Commercial Lead

Doncasters Bramah

+44 114 251 2051

jmarsh@doncasters.com

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Copyright Doncasters Group 2014 Strictly Private & Confidential