Manufacturing

Rewarded by the continual improvements made to our internal quality processes, we totally upgraded our quality management systems and on the 6th of October 2009 we successfully achieved certification to ISO 9001:2008, the fourth edition of the international standard. Regular training and KPI monitoring ensures that the rigorous and controlled processes required to maintain the highest level of quality control are adhered to throughout the organisation

Highly skilled technicians hand build every transmission with full build / rebuild records and certificates of conformity being stored on central database allowing full and easy traceability for serial numbers and build configurations.

Build integrity is checked with a repeatable test procedure conducted in a dedicated test area by a separate team of technicians. In addition to a final build test sub assemblies such as oil pump are thoroughly tested prior to fitment into the gearbox.

Should a customer’s programme demand, separate confidential areas can be created on a temporary or permanent basis.

A full range of Non Destructive Test techniques are used at Xtrac dependant on detection and certification requirements. We operate a full range of Ultrasonic detection, Nital Etching, Dye Penetrant and UVMPI (Ultra Violet Magnetic Particle Inspection).

Plant List

• Bassaire Clean Air Flow Bench
• Miller TIG Welding Plant
• Guson M350 Wash Tank

Ground spiral bevel gears, including hypoids, are manufactured using Klingelnberg KIMoS calculation software in a closed loop manufacture method. The manufacture process consistently provides high quality parts true to the original design specification.”

Spiral bevels up to 300mm in diameter and up to 100mm of hypoid offset with complete freedom to shaft angle; can be considered subject to design constraints. Hard cut spiral bevel gears, including hypoid by the Klingelnberg Cyclo-Palloid method can also be produced.

Plant List

• Klingelnberg KNC40 CNC Spiral Bevel Cutting Machine
• Gleason Straight Bevel Coniflex Generator Machine
• Klingelnberg G27 CNC Spiral Bevel Grinding Machine
• Klingelnberg MSN 20 Blade Sharpener

Xtrac is able to offer a range of different specification magnesium and aluminium castings with standard or ultra thin wall thicknesses. These can be sand, sintered sand or investment castings which are produced to extremely high quality control standards, including full dye penetrant inspection, X Ray to ASTM E155 and CT Scanning as required depending upon the application. These castings are, subject to size, machined within Xtrac’s CNC machining facility.

A selection of CNC wire and spark eroding machines are used for general machining operations and also for gear cutting operations to over come limitations with conventional processes such as hobbing and shaping where there is sufficient space for tooling run out.

Plant List

• Charmilles EDM Spark Eroder
• Charmilles EDM Spark Eroder 35P
• Charmilles EDM Wire Eroder 3040 SI
• Charmilles EDM Wire Eroder CC440
• Charmilles EDM Wire Eroder 240CC

Internal and external spur and helical form gear grinding by the Kapp method where dressable or CBN wheels are used to produce gears of master gear quality. Full on machine measurement technology and network links to the engineering department allow swift improvements and developments to be made to specific gear profiles.

Plant List

• Kapp VUS-55P Gear Grinder
• Kapp VUS-55P Gear Grinder
• Kapp VUS-55P Gear Grinder
• Kapp VUS-55P Gear Grinder
• Klingelnberg PEC 33 Checking machine

Xtrac has an extensive range of CNC machinery producing both involute and free form profiles and subject to peripheral considerations we are able to achieve parallel, tapered and non-orthogonal gear systems. Although traditionally, racing transmissions are spur gears, Xtrac has a philosophy and capability to manufacture all forms of spur and helical tooth profiles suitable for the most arduous racing application and the most demanding NVH properties required for today’s luxury saloon and electric vehicles.

Hobbed gear forms up to 300mm in diameter and up to 400mm lead.

Shaped gear forms from 4mm to 400mm and up to 120mm in lead.

Vertical broaching to form internal splines and gears.

Ground spur and helical gears both external and internal according to the Kapp method, by form grinding using ceramic and CBN wheels, up to 500mm in diameter.

Straight cut bevels to the Gleason Coniflex© System.

CNC chamfering for tooth clipping, rounding and free form leads.

EDM (Electrical discharge machining) is also used to form gear and spline profiles from the master CAD data.

Gearcutting Ratio Manufacturing Cell

Xtrac operates dedicated manufacture cells to achieve World Class Manufacturing Techniques, for Gear Ratios and Engine Timing Gears. The concept of the cell is to dedicate a complete facility that combines all of the manufacturing machinery, measurement equipment, knowledge and people, necessary to achieve a reliable, efficient and consistent product. Set up to minimise travel between machines, the cell improves part visibility and thereby planning to reduce manufacturing lead-times and continuous improvement to on-time delivery.

At the heart of the cell is a Cell Manager who is responsible for his team and his CNC machinery. Including Okuma twin spindle lathes, Matsuura hard machining mills, Pfauter hobbers, a vertical broach, a laser etcher, Studer grinders and a centralised inspection facility.

The use of quality improvement teams driven by Key Performance Indicators, provides continuous improvement where our multi-skilled operators are proud of their achievements and leading role to the Company.

Plant List

• Studer S 145 Grinder
• Studer S 145 Grinder
• Gleason Pfauter P90
• Pfauter PE150 CNC Gear Hobbing Machine
• Pfauter PE300 CNC Gear Hobbing Machine
• Pfauter PE250 CNC Gear Hobbing Machine
• Pfauter P300 CNC Gear Hobbing Machine Siemens Control
• Hahn & Kolb Laser Etcher
• Okuma LB 300
• Okuma LB 250T
• Matsuura Mill ES450H2 - PC5 pallet
• Matsuura MC550VX Vertical Machining Centre
• Pfauter P.S.A 300 Gear Shaping Machine
• Lorenz LFS 282 Gear Shaping Machine
• Pfauter P300S CNC Gear Shaping Machine
• Klingelnberg SNC 31 Hob Sharpener
• Gleason G.T.R 250VG Chamfering Machine
• Lapointe Broach
• TCE Wash Tank S500

Advanced CNC grinding machines are used for both cylindrical and surface grinding where C-axis operations can be performed for either off-axis grinding or where profile grinding is required.

Hauser CNC jig grinders are used where contour grinding or positional accuracy to within a few microns is required, all housed in a strict temperature controlled environment.

Constant improvements within the grinding processes have eliminated flecking and superfinish surface quality can be achieved on machine without the need for additional processes.

Plant List

• Studer S36 Favorite
• Studer S40 CNC Universal Cylindrical Grinding Machine with C Axis Head
• Studer S20 CNC Universal Cylindrical Grinding Machine
• Studer S40 CNC Universal Cylindrical Grinding Machine
• Hauser S35 CNN 600 Jig Grinder
• Hauser S35 CNN 600 Jig Grinder
• Hauser S35-600 CNC Jig Grinder
• Studer S40 CNC Universal Cylindrical Grinding Machine
• Studer S21
• Studer S21
• Studer S21
• Studer S31
• Studer S33 CNC Universal Cylindrical Grinding Machine
• Jones & shipman 5/200 2 Axis CNC Surface + Form Grinder
• Jones & Shipman 1400 x Electronically Controlled Surface Grinder (bowers)
• Jones & Shipman 540 x Electronically Controlled Surface Grinder (bowers)
• Jones & Shipman 1300x
• Jones & Shipman 1300 Universal Cylindrical Grinding Machine
• Jones & shipman 5/200 2 Axis CNC Surface + Form Grinder
• Jones & Shipman 540 x Electronically Controlled Surface Grinder
• Jones & Shipman 1300 Universal Cylindrical Grinding Machine
• Technica ZSM centre grinder
• Jones & shipman 524 Easy 2 Axis CNC Surface Grinder

Xtrac employ three CNC sealed quench furnaces which utilise complete monitored environment control during the carburising and quenching processes. Dependant on final material requirement, controlled sub zero freezers are used and temper furnaces ensure that the exact final mechanical specification is achieved.

At the heart of the shot peening facility is a 3-axis Vacublast computer controlled cabinet enabling either single or duplex shot peening processes which can pin point the shot jet to the exact surfaces required.

Plant List

• Ipsen Abar Single Chamber Tempering Furnace DL-6-E
• Ipsen Abar Single Chamber Tempering Furnace DAC-6-ER
• Ipsen Abar TQ6EMI Atmosphere Controlled CNC Sealed Quench Furnace
• Ipsen Abar TQ6EMI Atmosphere Controlled CNC Sealed Quench Furnace
• Ipsen Abar TQF-6-EMII CNC Sealed Quench Furnace
• Tempering Furnace (Stand Alone)
• Tempering Furnace(Wild Barfield) mod 2018VFC
• Indentec Hardness Testing m/c
• Zwick / Roell ST-2000 Hardness Tester
• Wilson / Rockwell Hardness Tester Series 500
• Nital Etch Process Line
• Magnaflux 40H Crack Testing Machine
• Buehler Abrasive Cutter
• Buehler Phoenix Beta Grinder / Polisher
• Hardness Tester Vickers
• Hardness Tester Vickers / Brunell
• Colchester Student 1800
• Rausch-Mastra De-Burring Machine Gratomat 300-HVSI
• Rausch Mastra
• Spencer & Halstead M101 Barrel Shot Peening Machine
• Vacublast VB 11254 Computer Operated Shot Peening Plant
• Spencer & Halstead M101 Barrel Shot Peening Machine
• Charmilles EDM - Spark Eroder - FORM 2-LC
• TCE CCH Solvac S1000 Degreaser
• Straightening Press MAE S25RH

Long term forward planning for material usage is essential for the long lead high specification and bespoke steels used in our transmissions and to enable us to maintain our ultra responsive delivery times we hold over 40 tons of our extensive material stock on site which allows us to commence manufacture of any component immediately.

Strict quality control through all stages of the material’s manufacture is ensured through our close relationship with the foundries and continues with spectrographic testing of billets on receipt and prior to preparation for processing in our various manufacturing departments.

Plant List

• Spectrotest - TJF7CO2F
• Bridgeport Series 1 Universal Mill
• Startrite 30R.W.H Vertical Band Saw
• Pedrazzoli Mel Brown 75 Hand Circular Cut-off Saw
• Kaltenbach/Behinger HBP 303A Automatic Band Saw
• Kaltenbach/Behinger 260A Automatic Band Saw
• Anbas  Trau200 Auto Protection Band  Saw
• Kaltenbach/Behinger HBP360A Automatic Band Saw
• Kaltenbach/Behinger HBP263A Automatic Band Saw
• ORT Thread Rolling Various Sets of Rollers
• Forklift  SAS 25-42-7FGF25
• AJH Band Facer (belt sander)

Data from engineering is downloaded directly to the dedicated Milling CAD/CAM programming facility and processed using either Unigraphics or Edgecam CAD/CAM software. A dedicated inspection area gives the benefit of using a master model concept for both programming and quality control. This helps to maintain a high standard throughout every stage of production and inspection and gives an unrivalled ability to offer a fast and flexible response.

Plant List

• Mori Seiki CNC Vertical Milling Machines (4th Axis Attachment)
• Mori Seiki CNC Vertical Milling Machines (5th Axis Attachment)
• Hitachi Seiki HG 400 Horizontal CNC Milling Machine H8 with Fanuc Control & High Speed/Contour Control
• Hitachi Seiki HG 400 Horizontal CNC Milling Machine H11 with Fanuc Control & High Speed/Contour Control
• Matsuura V+1000 Vertical with Nikken 4th Axis
• Matsuura MAM 72 Five Axis CNC Mill with Pallet Loading & High Speed / Contour Control
• Matsuura ES 450H Horizontal CNC Mill with Pallet Loading & High Speed / Contour Control
• Matsuura MC 660 Vertical CNC High Speed Mill with Nikken 4th Axis
• Hitachi Seiki, HS630 Horizontal Machine Cell with Pallet Loading + 4th Axis
•  Matsuura MAM 72 - 25 Five Axis CNC Mill with Pallet Loading & High Speed / Contour Control
• Matsuura R+550 Twin Pallet Vertical  
• Matsuura R+550 Single Pallet Vertical  
• Matsuura RA 2 Vertical CNC Mill with Pallet Loading & High Speed / Contour Control with Nikken 4th Axis
• Hurco Milling Machine with 4 Axis Dividing Head
• Huron Universal Milling Machine
• Ajax AJJ 4 Milling Machine with Sony Digital Readout.
• Ajax Manual Mill. F.U.T.V. 140 Universal Head, Vertical

To maximise all of the engineering and manufacturing expertise which goes into our components, every part is hand finished to ensure that they are fit for use as soon as they are received by our customers. Attention to detail at this key stage is paramount to ensuring maximum reliability.

Plant List

• Excel Optimum Lathe
• BUD Lathe
• MAFAC Parts Washer
• Air Bench x 3
• BURR Bench BB40 Rumbler
• AE5000 50 Variable Speed Polisher
• Wash Tank

Investing design time into the master model enables Xtrac to produce resin patterns directly from machined data or to transfer the CAD data for rapid prototype manufacture using stereo lithography or sintered sand moulds. The rapid prototyping techniques have many benefits and can be successfully used:-

• For thin walled castings where absolute precision is required either directly as a pattern or through the lost wax process
• To reduce the lead time for initial gearbox deliveries
• To provide engineers with a ‘finished structure’ for evaluation purposes and to aid initial car build
• To save costs and time where design alterations to the pattern are required

For longer production runs hard resin patterns are employed for their durability and stability whilst still benefiting from short manufacturing lead times.

Xtrac's quality system is constantly refined to meet the ever-increasing expectations of our customers, whilst remaining conscious of the needs of the organisation. The continual use of standard operating procedures developed through team working, ensures that staff at all levels understand what is expected of them, and appreciate the importance of customer satisfaction.

Quality is delivered through the close monitoring of all processes in line with ISO 9001 procedures utilising a full range of testing equipment and electronic instrumentation. From receiving raw materials to supplying finished assemblies and components, every step is recorded offering Xtrac’s customers the confidence of knowing that they are receiving consistent and repeatable quality.

A fully qualified Metallurgy Laboratory serves to maintain integrity in material selection and associated heat treatment processes. Vital quality records are produced and supplemented by First Article Inspection Reports and Control Plans. Customer specific quality requirements are incorporated within our procedures together with specific customer standards. Key performance indicators are employed to maximise the contribution that individuals make to the success of the organisation. The resulting information is routinely analysed and used as the basis and measurement for any resulting improvement actions.

An ongoing structured capital expenditure plan ensures that the customer's expectation is matched by Xtrac's measurement capability and in doing so enables the company to continually face the challenge of producing the highest precision parts possible.

Plant List

Main Inspection

• Zeiss Prismo CMM
• Klingelnberg P40 Gear Measuring
• Klingelnberg PNC35 Gear Measuring
• Mitutoyo BHN706 CMM
• Mitutoyo BHN706 CMM
• Mitutoyo BHN706 CMM
• Mitutoyo PH3500 Profile Checker
• Mitutoyo Optical Profile Checker
• Hahn & Kolb Laser Etching Machine
• Hahn & Kolb Laser Marker

Metallurgical Inspection

• Buehler Abrasimatic 2 - Automatic Abrasive Cutter
• Buehler Simpliment 100 Automatic Mounting Press
• Beuhler Beta Grinding Polisher Twin Table
• Beuhler Beta Grinding Polisher Twin Table
• Beuhler Beta Grinding Polisher Single Table
• Beuhler Micromet 5100 Series
• Leica MZ75 10 - 50
• Leica DM1RM 50 - 1000
• Nikon Optiphot 10 - 50 (used for photo's)
• Nikon SMZ2T 50 - 500 

Satellite Inspection

• Mitutoyo CMM BHN506
• Mitutoyo Euro Apex CMM (Euro C - A9106)

Xtrac have developed two surface enhancing processes dependant on the final surface finish requirements and control of the parent geometry. XTREM is based on a vibratory platform and utilises a tumbling ceramic media to lightly polish all contact areas. XTEC is a spindle driven process that requires the components to be moved through a fine organic media. Irrespective of the process used, the improvements to the surface factors are proven to increase both fatigue life and contact stresses.

Plant List

• DF70 Drag Finishing Machine
• DF70 Drag Finishing Machine
• Air Bench
• Walther Trowal CM305 Vibratory System
• Walther Trowal CM405 Vibratory System
• Walther Trowal VN Vibrator with Acoustic Enclosure
• Walther Trowal CM405 Vibratory System

Ultra modern equipment, primarily CNC includes up to 5-axis machining with both horizontal and vertical platforms. Master model data is transferred into Xtrac’s off-line programming facilities and once processed is downloaded direct to the relevant machine tool. The introduction of driven tooling has enabled combined machining processes resulting in more efficient manufacture with reduced set up. Developments on cutter technology and coatings allows increased amounts of hard machining to produce previously unachievable surface finish and tolerance, without the need for grinding.

Plant List

• Okuma LB 25 CNC Lathe
• Okuma LB 15 CNC Lathe (Parts Catcher)
• Okuma LU 15m CNC Lathe twin turret turn / mill
• Okuma LCC 15-2S CNC Lathe twin turret
• Okuma LB-10 2m CNC Lathe 8" chuck turn / mill
• Okuma LU 15m CNC Lathe twin turret turn / mill
• Okuma LB 300 CNC Lathe
• Okuma LB 300 CNC Lathe Long Bed
• Okuma LU 300 CNC Lathe big bore 12" chuck twin spindle
• VS2500 Colchester Manual Lathe/Anilam
• VS2500 Colchester Manual Lathe/Anilam
• Colchester 2500 acurite