From sketch to finished part, Complete Engineering Services delivers for Sam

When not busy running Carlisle-based Complete Engineering Services, co-founders and joint managing directors, Alan Walker and Andrew Monkhouse enjoy their motorcycles, in particular road racing. This passion has seen them work with several riders to develop their race bikes and, in 2018 to celebrate Complete Engineering Service’s 20th anniversary they sponsored the race helmets of WNT Burman Racing’s Sam Burman.

For the 2019 HEL Performance British Motostar Championship Sam has a new motorcycle and Alan and Andrew decided to increase their involvement with additional sponsorship of the team, part of this was the offer to machine components for the bike that would not only improve the performance of the bike through weight reduction, but also improve its looks through component design. Eager to take up the offer Sam and her father Phil provided sketches of the parts required, which included fairing brackets, rear brake rods, mudguard bolts and a specialist ride height tool. All manufactured from a mix of aluminium, stainless steel and titanium. “The sketches were detailed but when we gave them to our Sam, who programs and operates our Mikron five-axis machining centre, he wanted to develop them further,” says Alan Walker. “As the bike is situated some distance from us, we modelled up the parts and emailed designs across to Sam, for a stage approval, we then produced sets of ‘trial parts’ for fitting to the bike. These then will of course, be tested on track as part of the ‘shakedown’ process, so now the race is on getting everything ready for the start of the season.”

Transferring the original drawings to CAD files allowed Sam to create parts that were both aesthetically pleasing and functional, making use of the five axis capability and a selection of WNT cutting tools from Ceratizit UK & Ireland, including diamond-like coated solid carbide milling cutters, ALU line milling cutters and the WNT ZSG4 workholding solution that allowed parts to be gripped on minimum material so that they could be ‘snapped off’ once machined. A further advantage was the fact that all of the WNT tools and workholding systems come with CAD files, making programming straightforward, while the Diamond Like Coated milling cutters allow elevated cutting data to remove material quickly. “Ceratizit UK & Ireland’s Matt Darbyshire introduced us to the DLC cutters when they first came out and we have never looked as they are now our first choice for ultimate metal removal and surface finish!’