• ENHANCED
    PRODUCT
    DESIGNS
  • ENHANCED
    PRODUCT
    DESIGNS

COMPLEX
COMPONENTS

MANUFACTURED ENTIRELY IN-HOUSE

The close relationship between design, production engineering and manufacturing ensures that even the most complex components are able to be manufactured. Our commitment to researching new processes and manufacturing techniques has enabled enhanced product designs.

The demands for short lead times and unmatched quality are everyday challenges at Xtrac. The ability to manufacture components entirely in-house is paramount in satisfying both demands. Our policy of continual investment in the most sophisticated and efficient CNC machines and CAE capability enhances existing capabilities and adds new in-house processes, allowing us to meet, and exceed, our customers’ requirements.

Our hi-tech manufacturing facility, which is state of the art, allows products to be delivered to the highest standards of quality and within vastly reduced lead times. The production engineering team supports the manufacturing departments to ensure that Xtrac’s quality is always achieved.

QUALITY CONTROL

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 9001:2015 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.

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Accreditations

Rewarded by the continual improvements made to our internal quality management system, we successfully achieved certification to ISO 9001:2015 in January 2018. 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.

Quality Management Certificate

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ASSEMBLY

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 dependent on detection and certification requirements. We operate a full range of Ultrasonic detection, Nital Etching, Dye Penetrant and UVMPI (Ultra Violet Magnetic Particle Inspection).

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BEVEL GRINDING

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.

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CASTINGS

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.

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GEAR GRINDING

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.

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GEAR CUTTING & BROACHING

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.

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GRINDING

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.

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HEAT TREATMENT & SHOT PEEN

In addition to their state of the art Ipsen Turbo 2 Vacuum furnace, Xtrac employ three CNC sealed quench furnaces which utilise complete monitored environment control during the carburising and quenching processes. Dependent on final material requirement, controlled sub zero freezers are used and temper furnaces ensure that the exact final mechanical specification is achieved.

The Ipsen IDAC vacuum temper furnace is principally used for annealing operations with reduced energy consumption and increasing efficiency whilst solving the potential safety issues present with conventional atmosphered furnaces. The furnace operates by evacuating the working zone before back-filling with inert nitrogen to achieve good heat transfer, temperature uniformity together with non-oxidising properties. Components, which are required to undergo prolonged annealing cycles, emerge clean and oxide free with excellent levels of surface integrity.

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.

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MATERIALS

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.

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MILLING

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 satellite 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.

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PARTS FINISHING

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.

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TURNING

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.

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SURFACE FINISHING

Xtrac has developed two surface enhancing processes dependent 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.

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