Rapid Development Compressor

Transcription

1 Rapid Develpment Cmpressr Cmpnent Manufacture Study with NATEP 2017 Reprt Rev 1-1

2 PROJECT Prject Objectives Manufacture f lw vlume, variant Cmpressr cmpnents frm standardised Oversized Frging inputs Delivery f a slutin nt currently prvided by market ptins: Precisin Frging due t lead times & MOQ s Make frm Bar due t metallurgical cnstraints and cnditins Innvatin thrugh delivery f lw vlume cmmdity prcess expliting high vlume methdlgies prviding: Reduced NPI Requirements Imprved Overall Cst & MOQ Pints vs. Precisin Frgings Custmer Lead Time Requirements Need highlighted by multiple custmer RFQ s fr cmpnents frm Precisin Frgings Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

3 PROJECT Partners and Rles MB Aerspace Newtn Abbt (frmerly Centrax TCL) Wrk with all partners n cllabrative frging Design Design and Manufacture fixtures R&D int machining strategies and techniques Machining and cmpnent testing Mettis Aerspace Design and manufacture tling arund cllabrative frging design Prvide test batch f cmpnents West Cuntry Tl C. Research and develp cutting strategies utside current knwledge Rlls Ryce PLC Prviding end custmer supprt including access t cmpnent designs and metallurgical assessments at prject cmpletin Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

4 PROJECT Wrk Packages and Plan WP1 Oversized Frging Develpment MBANA, Mettis & RRplc t wrk cllabratively n cmpnent chice and flexible frging design t create a batch f input stck fr machining WP2 Machining R&D Cllabrative Industrial R&D between WCT & MBANA int cnsumables, cutting methdlgies and equipment Creatin f jigs and fixtures arund frging design Mill and grinding trial and develpment activity WP3 Cmpnent Testing MBANA lab t wrk with RRplc n testing f finished cmpnents and metallurgical standards Cut Ups & Nn Destructive Testing WP Milestne Q1 Q2 Q3 Q4 Q5 Q6 1 Cmpnent data and develpment f design 1 Prductin f frging die and frging batch 2 WCT cnsumable tl research 2 MBANA Industrial R&D int machining 3 MBANA in-huse testing prcesses 3 Testing with RRplc & agreement n future Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

5 PROJECT Prject Deliverables Key deliverables f the prject are as fllws: Technical Scpe Agreement Frging Design Develpment Frging Manufacture Machining Research Prduct Manufacture Testing & Analysis Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

6 METTIS MBNA Frging DFM Optimise material requirements Frging manufacturing cnsideratins Machining strategy cnsideratins Incrpratin f service feature fr MBANA methd Minimum prcessing Frging Machining Nminal material envelpe established Manufacturing tlerances understd and mitigated Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

7 METTIS Frging Prcess Develpment Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

8 METTIS Prcess Optimisatin Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

9 WEST COUNTRY TOOLS Typical Cutter Trials Data used and achieved results C O N F I D E N T I A L C O N F I D E N T I A L C O N F I D E N T I A L Cated tl Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

10 WEST COUNTRY TOOLS - MBANA Cutter Investigatin Research the use f Ceramic end mills n machining Incnel 718 Cmpressr blades. The use f Ceramic end mills in the manufacture f Turbine blades is generally fr rughing and semi finishing. Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

11 WEST COUNTRY TOOLS - MBANA Clant Trials Benchmark against 16mm tl life and expectatins n Inc 718 material Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

12 WEST COUNTRY TOOLS - MBANA Clant Trial - Matrix Fluid Manufacturer Cst per litre Tl Life Sump Life Ec Friendly Overall Rank Remarks A 1 1x 1 12 Yes 8 Original prduct. Intrduced in 2014 acrss site. Pr tl life but surface finish and sump life acceptable B 1? 1 26E Yes 11 Able t tell straight away that clant was nt crrect fr applicatin. Rapid tl wear C 1 1x 1 1 Yes 7 Initial results lked very prmising with 3 parts per tl. Clant brke dwn within week reducing cunter t 2 then 1 part D 1 0.9x 2 6 N 1 Chlrinated prduct. Old technlgy still perfrms the best. Shrt sump life and knwn t aggressively attack machine hardware E 1 1.6x 1 26E Yes 6 Better wear than riginal clant but unable t extend tl life beynd 1 part F 2 2x 2 6 N 4 Due t be phased ut 2016 (Reach). Used currently n site. Previusly used n this part. Life and finish gd G 2 2.3x 1 26E Yes 9 Recmmended replacement fr clant F starting Jan 16. Visibly pr surface finish. Tls breaking dwn early H 2 2.2x 2 26E Yes 3 Incnel specific technlgy. Tl life and surface finish gd. Ec friendly prduct but high cst per litre I 3 1x 1 26E Yes 5 Tl life marginal between 1 and 2 parts. At 1 part lks very gd but then breaks dwn after 2 beynd regrind state J 3 1.1x 1 26E Yes 10 Tl life very pr. Immediately nticeable that fluid was nt ging t be right fr this applicatin K 3 1.3x 2 26E Yes 2 Gd tl life. Fluid nw been in machine fr 6 weeks. Manufacturer believes sump life t be 6 mnths MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary Page 12

13 MBANA Adaptive Prgramming Reductin in nn cnfrmance frm 90% t less than 1% n difficult t measure features Machine uptime imprved by 25%-30% due t the cmpnents being crrect and nt being measured after the machining Operatrs need far less training, and hence are less likely t make errrs Machines run 1 standard prgram fr 5 Axis machining, and the machine datum psitins are all that alter Less verprductin due t better Right first time figures Imprved Prfitability Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

14 MBANA Machine Optimisatin 3 axis (X,Y,Z) ballbar test that diagnse faults with linear axis. This can be wear, backlash, fllwing errrs etc 5 axis ballbar that tests all machine axis fr faults. accurately determines the gemetric psitins f rtary axis Setup errrs resulting in verall Q value (accuracy) 0,16mm Mapping these gemetric values back t the kinematic table reduced this errr t 0,06mm Mechanically the unit was acceptable. A axis acceptable B Axis lcalised errrs Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

15 MBANA Finished Part & Reprting Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary

16 PROJECT Cnclusin Objective f prject has been achieved Oversize frging develped Cutter and cut strategies investigated and ptimised Innvative machining strategies develped and implemented Demnstratin parts prduced Initial material investigatins successful Prject has prvided supprt t enable pursuance f market pprtunities Page MB Aerspace Newtn Abbt Limited Cnfidential & MB Aerspace Prprietary