Our Processes

Below we explain our processes from manufacture through to finishing.

 

 

Manufacture >
Product manufacture is carried out on small modern industrial site in Partridge Green, West Sussex, UK.

The workshops are equipped with the following:
  • One Aberlink Axiom Too co-ordinate measuring machine
  • Four CNC millsThree CNC lathes – setup for soft and hard turning
  • Four gear shaping machines
  • Two spline & gear hobbing machines
  • One turret mill
  • One lathe
  • 7 ton vertical broaching machine
  • Surface grinding machine
  • Usual jobbing workshop equipment


The CNC machines comprise of a Daewoo Lynx and 2 Doosan 220 chucking lathes, Four XYZ 560VMC machining centers two with 4th axis capabilities. The four machining centres are fitted with 16 position tool changers. All the CNC machines are linked to computers for DNC machining Software used for CNC machining is OpenMind Hypermill 3 axis

Gear Manufacture
The shaft or gear blanks are turned on our CNC lathes, all programs are written offline. Engagement dogs and lightning pockets are cut on the CNC machining centres.
Teeth are cut either by hobbing or shaping, depending on the design of the gear using high quality cutters. Splines on shafts are hobbed.
Once fully de-burred all parts are marked up and sent to heat treatment for hardnening.
All components where necessary are then finished by hard turning on a CNC lathe
Where applicable parts are then Superfinished.

At each stage of manufacture we are able to check dimensional and geometric accuracy of components using our automated measuring machine.

Aluminium components
Aluminium components, are billet, machined on the machining centres. Aluminium specifications used are NS8 and HE30. Following machining and inspection, the components are usually either hard or decoratively anodised

Materials >
No matter how good the design and manufacture processes are, it remains an aknowledged fact that the material and subsequent heat treatment is the most important part of our products.

Whilst commercial EN36 has served well enough since its introduction in 1941, hence the "emergency number" designation, improvements have taken place in the elimination of impurities.

With quality in every aspect of our products being the most important obective, the decision was taken in 2009 to find a new supplier. Enquires around the automotive transmission manufacturers lead us to the Austrian company Bohler, long famed for their tool steels, who had recently introduced a range of gear steels produced in a novel, to us, way with no measurable impurities. Effectively EN36 modernised. With a level of support for their product not experienced previously, we look forward with confidence to be able to off the best possible product to motorcycle engine users.

Heat Treatment >
We have used TTI Luton for 34 years, as do many top engineering companies, F1 teams and leading transmission manufacturers.

Tests to date with our most highly stressed product using Bohler Steel, T.T.I. Heat treatment and Superfinishing has proven to be superior when compared to our previous supplied material without the Superfinishing.
 
Superfinishing >
To further enhance the quality of our products we can offer Superfinish as an optional treatment at an additional cost.

The Superfinishing process produces a highly polished surface to resist the propagation of fatigue cracks and to reduce friction.

Price £10 Per Gear**

We will also Superfinish standard components on request, please contact us for a quote.