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NIKKEN Supports Sheffield Formula Racing
NIKKEN recently supported Sheffield Formula Racing, the University of Sheffield's student racing team, with Manufacturing Engineer Alex Law producing a set of precision front uprights for this season's car.
Formula Student challenges teams to design, manufacture and compete with a single-seat race car, demanding exceptional levels of engineering, precision and innovation. Every component must be lightweight, highly accurate, and capable of performing under demanding race conditions.
Having previously supported with machining components for the rear differential, this latest collaboration focused on one of the vehicle's critical suspension components.
High-Speed Aluminium Machining
Manufactured from 7000 series grade aluminium, using advanced trochoidal and High Efficiency Milling (HEM) strategies, the components were machined with a combination of NIKKEN tool holding solutions each selected specifically for the operation being performed.
- Initial roughing operations were completed using an FMH facemill arbor fitted with a Ø50 mm facemill. The rigid arbor allowed high material removal rates during the initial roughing stages, providing the stability required while maintaining process reliability.
- Semi-finishing operations were carried out using the Multi-Lock milling chuck. With extended reach tooling required to access certain features of the component, maintaining rigidity became essential. The Multi-Lock's market-leading gripping force and exceptional rigidity allowed stable machining even when using cutters with longer flute lengths.
- All drilling operations utilised a Mini-Mini chuck. Its mechanically sealed design ensured through-tool coolant reached the cutting edge efficiently, while the compact nose diameter improved access around the component.
- For profile finishing and final machining operations, the Major Dream slim chuck was chosen. Designed with advanced vibration damping characteristics, the Major Dream helped minimise chatter during finishing, producing the high-quality surface finish required for critical functional surfaces. The holder was also used alongside an end mill to machine the main featured bores, where stability and precision were paramount.
Complete Hole-Making Solutions
While this project utilised an end mill to machine the primary bores, NIKKEN also offers a comprehensive range of dedicated boring systems for precision hole-making applications.
Solutions including the ZMAC, DJ and RAC boring systems provide manufacturers with accurate, repeatable and highly productive options for roughing, semi-finishing and finishing bores across a wide variety of machining applications.