NTR Limited

Company Credentials

www.ntrltd.co.uk

Contents

• Background

• EN ISO 9001-2008 & Fit for Nuclear (F4N)

• Tooling Reclamation

• Services– Reclamation of Workholding

– Manufacture of Special Tooling

– Repair & Rebuild of Driven Tooling

– Regrind & Recoat of HSS & Solid Carbide tools

– CHAM Drills

– New Tooling

– Mandrel Tube bending tooling

• Our customers

• What our customers say

• Product Research

• Case Study

Background

NTR Limited

• Established over for over 30 years, we lead the field in the repair of pocketed tooling.

• Our continual commitment to process and product improvement has meant that as tooling technology has advanced so have we.

• Today, NTR is proud to offer you a complete tool room service covering all your cutting tool requirements.

• We deliver saving of 65% on the cost of new tooling

• With a standard 2-week turnaround on all repair tools, we lead the field in tooling reclamation.

• We are ISO9001:2008 certificated and currently in the process of being approved to supply the Nuclear Industry via the Nuclear AMRC, F4N program.

NTR Vision & Mission

Vision

To be the number one provider of reconditioned

pocketed cutting tools through exceptional quality, customer service and on-time delivery.

Mission

The company's mission is to be successful in

the provision of reconditioned tooling by

effectively enhancing our people, technology and

customer service to deliver product excellence.

Tooling Reclamation

Services

Tooling Reclamation

• With nearly 40 years machining experience, NTR have assembled

and trained the best group of manual milling and fitting engineers

within the sector. Over the many years we have been repairing

pocketed tools our staff have developed some of the most advanced

techniques within the industry which is why so many customers

entrust us to repair their tools.

• Technological advances have also assisted and we now use a

combination of manual and 5-Axis CNC technologies to ensure your

tools are repaired to perform and look as new.

• CNC machining of pocketed tooling now means that cutting tools

once considered scrap or beyond repair, can now be renewed.

• Most U-drills, CAPTO, KM/BT block tooling and Ball Nose cutters

are repaired on CNC.

• In all cases coolant holes are fully restored.

Cutting tools reconditioned by NTR Ltd

Company Video

www.ntrltd.co.uk

HURCO VMX30t

Manual Milling

Pocket Profiling

Stage 1: Tool with

Outer Diameter and

pocket areas badly

damaged.

Stage 2: The drill is

strip-down and pockets

cut out. This enables us

to assess the structural

integrity of the tool and

also provides assurance

of proper deposition of

the root weld.

Stage 3: The drills is

welded using our

advanced precision

welding technology and

metallurgy study that

guarantees compatibility

between base metal and

filler rod.

Stage 4:

The pockets are

milled and finished

to the required

quality standard

using our integrated

CNC technology to

guarantee the

tolerance.

Stage 5: At final

inspection the

screw holes,

tolerance and

finish quality are

verified. The tool

is then labelled,

oiled and packed

for delivery.

Example: Reclamation process for a Short Hole Drill

Example 1

Stage 1: A Long Edge Milling

Cutter and Face Mill with the

top pocket severally damaged.

Stage 2: The tool is

stripped-down ensuring

any “pick-up” is removed.

The damaged pocket

has been welded using a

filler rod that closely

matches the parent

metal. This guarantees

the tool longevity during

use.

Stage 3: Pockets are

then precision milled, the

outer diameter re-

grounded using our

flexible machining

capabilities and

calibrated measuring

equipment.

Stage 4: Tool finished, screw holes

are precision drilled, tapped and

countersunk. The tool is deburred

before it is polished.

Stage 5: Tool is bead blasted and

inspected - screw holes, tolerances

and finished quality are all verified.

An inspection certificate is

prepared before it is labelled (our

seal of quality), oiled, packed and

shipped.

Example 2: Face, Shell, Shoulder and Long Edge Cutter reclamation process

Example 2

Stage 1: Capto tool holder with outer

body and pocket area badly

damaged.

Stage 2 (Not in Picture): The pocket is

stripped down, contaminates and

damaged areas are ground away

guaranteeing the micro-structural integrity

of the weld substrate.

Stage 3: It is then welded using our

advanced precision welding technology

ensuring compatibility between base

metal and filler rod.

Stage 4: The pocket is Milled,

Finished and glass bead blasted.

Stage 5: At Final Inspection screw

holes are checked, the tolerance

measured and finished quality

verified. The tool is then labelled,

oiled and packed ready for delivery.

Example 3: Capto, External Tool holder reclamation process

Example 3

Financial & Environmental

Benefits

• Tooling Reclamation has always been synonymous

with cost savings and it is no different today with an

average 65% saving on the cost of your new tooling.

• Of equal importance, is the need for companies to

recycle and renew.

• By using NTR we can help off-set your carbon

footprint.

Environmental as well as Cost Saving

benefits from NTR

Europe’s Leading Tooling Repair specialist

Seating accuracy and how to avoid

coolant contamination

• CNC machining innovation and advances in material science has enabled tooling to be repaired which once would have been considered be scrap.

• We are the only tooling reclaimer to glass bead polish your tools which not only guarantees seating accuracy, avoiding blocked threads but it also prevents coolant contamination resulting from paint & chemical lacquer coating.

Competitive Advantage

• NTR has a number of significant competitive advantages that differentiate us from our competitors:

– Reclamation know how developed over 40 years

– Cross functional teams encouraging innovation and

best practice

– EN ISO 9001:2008 Quality system

– Automated CNC machining using HURCO licensed pocket software

– Customer service and company culture delivering productexcellence

– Knowledge Transfer Partnership with Bradford University

– MAS Interventions in process improvement

– Application of LEAN, JIT, MRP, MRPII, FTQ and 5S into businesssystems

– Fit for Nuclear (F4N) supply approval

Collection & Repair Service

1. Your damaged tools are collected by our network of representativesback up by a national courier service through FedEx.

2. Tools are pre-inspected and booked in before being quoted &confirmed.

3. Leading edge welding combined with manual and CNC Millingtechniques are used to rebuild the tool body and pockets.

4. Hand finishing, glass bead blasting combine to produce a highquality finish.

5. Final inspection guarantees your tools are within the acceptedworking tolerance, before they are returned.

ISO Registration & Quality

• EN ISO 9001:2008 accredited we have invested in leading edge measurement equipment to guarantee cutting accuracy, each and every time your tools are repaired.

• All rotary tooling comes with its own inspection certificate detailing the maximum radial and axial run out.

NTR Twin Scope Royal

Tool

Pre-setter, which we use in

the final inspection of

tooling.

Other Services

Rapid Response Service

• Customers are offered a rapid response service providing a 24-hour-a-day, seven-days-a-week turnaround, dependent upon need. A premium is applied based on the speed of service required.

Provision of Spares

• In most cases a wide range of spares from leading manufacturers can be provided for those customers wishing to use this additional service.

Tooling Modification

• NTR can also undertake a variety of pocket modifications to suit different types of inserts, cutting diameters and other critical dimensions.

Inside NTR Limited

Working through a network of Representatives & Agents both here in the UK and Overseas we occupy 8,000 square feet of manufacturing area and 3,000 square feet of office space and

currently employ 26 people.

NTR’s European Network

Reconditioning

of

Workholding

Chuck Jaws

Before & After Reconditioning

Jaws are welded before being machined on CNC.Specialist weld & Heat treatment returns tools to minimum 60HRC

Chuck Jaws

Before & After Reconditioning

A 65% cost saving can be achieved on reconditioning work holding. Jaws can be repaired many times over before

they are deemed scrap

New Tooling

Manufactured from Drawing

Manufacture of New Tooling• In addition to the repair and recondition of pocketed tooling we

now have the capability to design and manufacture one off and

low volume special new tools.

Manufacture of New Tooling 2

• Using ZW 3D CADCAM software we can design and develop pocketed cutting tools

to suit your exact needs.

• Low volume or one off special tools are our forte and whether it be single pocket or

complex multi-pocketed tooling we will work with you to ensure your

tooling requirements are met.

• In house 5-Axis machining using HURCO's latest VMX30t CNC with built in pre and

post measurement means you can expect the very best results.

•

CADCAM & CNC specifications:

• Our CAM system is ZW 3D CAD/CAM

• File extensions that can be managed include: IGS, STEP, STL, PS3, Parasolid file

(x_t), DXF, DWC, Catia Graphics (CGR), Pro e Part (PRT), Solid works part file

(SLDPRT) and Inverter part file, (IPT)

• Dimensions: The VMX30t table size is 1020x510 and axis travel is x y z 762x508x610

Further examples

New Tooling

Modification work

Examples Include:• Skiving, Boring, Counter Boring and Taper Boring Heads:

Deep hole drilling

Turnaround Times

• We not only manufacture but design tooling.

• Activity undertake:

– Bespoke design

– using pre-existing drawings

– Taking details from the actual component to be manufactured and advising on

the tool design & manufacture

– Presenting ‘Estimated Quotes’ for work yet to be secured by the customer

• We offer a significantly improved turnaround time for the

manufacture of new tooling.

• On average we aim to offer a 3 to 4 week delivery schedule, sooner

if required, dependant upon size of order.

The Repair & Rebuild

of

DRIVEN / LIVE Tooling

Driven Tooling

Repair & Rebuild Service

• We repair & service all makes and models of Driven tooling offering SAVINGS of up to 65% on the cost of a new replacement unit.

• A quotation will be submitted for replacement and upgrading of parts including full rebuild and repair.

• All tools are fully tested and certified with annual maintenance contracts available on request.

Examples of Driven Tooling that

can be repaired

Regrind & Recoating

of

Solid Carbide & High Speed Steel

End Mills and Drills

Regrind & Recoat of Solid

Carbide & HSS

• For all your Solid Carbide and High Speed Steel tools, we offer

a full regrind and recoat facility.

• Operating licensed software on state of the art ANCA RGX CNC

machines we produce the original manufacturer’s cutting

geometry each and every time your tools are reground.

• Cutting performance can be further enhanced through a choice

of world class coating technologies from Oerlikon Balzers.

Regrind & Recoat of Solid

Carbide & HSS Tooling

Examples of Drills and End Mills reground and recoated by NTR

CHAM Drills

• Of growing benefit is the

Regrind and Recoat of

CHAM Drills saving

customers on average 60%

on the cost of new.

• Ranging from 8mm to

25.5mm all sizes can be

accommodated and

returned to the

manufacturer’s original

cutting geometry.

NTR are proud to

work with the

following Customers

Automotive customers include:

Aerospace customers include:

Some of our other customers:

“What our customers say”

What is the single most important factor

in determining your reclamation

provider?

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

Quality Price Customer

service

Reliability Delivery Technical

support -

67% of customers said that the single most important factor for

use us against our competitors is because of our quality.

Overall how do you rate NTR's quality?

0%

10%

20%

30%

40%

50%

60%

Very poor Poor Neither

poor nor

fair

Fair Good Very

good

Excellent

96% of customers rated our quality as Good to Excellent

Overall how do you rate NTR's

customer service?

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

Very poor Poor Neither

poor nor

fair

Fair Good Very

good

Excellent

88% of customers rated our customer service as

either Good to Excellent

What do you consider to be a standard

turnaround time for reclamation?

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

4 weeks 2-3 weeks 2 weeks 1-2 weeks 4 weeks or

less

6 weeks

75% of customers agreed that a standard turnaround time for

reclamation was between 2-4 weeks.

We offer, as standard, a twoweek turnaround

How could NTR improve its customer

service?

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

Quicker

turnaround

Offer free

delivery

It's OK Service is

very good

Delivery

times

reduced

No

response

There was no indicative response as to how we could improve

our service

NTR now offer a rapid repair service

24hrs to 1-week

Product Research

Prepared by Durham University

&

Conducted in 2008

Aim & Objectives

Aim

• To quantify the performance of our reclaimed tools with respect to new tools.

How? To determine:

– Tool Life

– Cutting Accuracy

– Insert Life

Tool & Component details

• Component to be machined: 12mm Holding Union

• Tested performance of a: Seco 8mm Boring Bar

• Measure the Offsets Introduce during the course of machining

• 2 Passes Made

• Total Depth of Cut = 0.5mm (doc)

• Feed Rate = 0.14 to 0.02 mm/rev

• Spindle Speed = 2500 rpm

Tool Hardness

60

25

26

38

59

26

25

25

Refurbished

Tool

New Tool

Results

-0.06

-0.04

-0.02

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0 100 200 300 400 500 600 700 800

Parts Produced

Off

set

Intr

oduced

New Tool Refurbished Tool Expected Results

Observations

• Refurbished tool ended with a positive cumulative offset– Bending?

– Pocket Deformation?

– Not Significant?

• The new tool required more inserts– Abnormalities on the Pocket?

– Weaker Inserts?

– Freak of Nature?

Observations & Conclusions

• Both tools required the same number of Offsets

and of similar magnitudes

• Equal amount of time spent altering machine

• NTR’s Reclaimed Tools Performed like New in a

Variety of Applications

• Further Research is Needed in Several Areas

• Current Reclamation Process Produces

Consistently Good Tools

Customer

Case Study

ToyotaProblem facing Toyota:

– Poorly managed tooling reclamation service resulting in repaired tooling notbeing compliant to drawing and rusting.

Solution:

– NTR worked with Toyota to agree a formalised process for tooling repair inorder to address the above issue.

Process:

– All tooling is reworked to drawing

– Spares identified and an order placed in advance before work commences

– Tools are repaired to specified tolerance and issued with certificate

– Tools are then oiled and bagged to avoid possible rusting

– Before being returned by NTR to the store department

This is a Premium Service offer to Toyota.

Questions?