Milling tough materials

Transcription

1 GF AgieCharmilles aerospace applications

2 flightpack It s all about your application

3 FACT GF AgieCharmilles through its worldwide network can provide customers with fast, in-depth and comprehensive applications support and advice. Thousands of precision manufacturing companies in the UK are involved (totally or in part) in the aerospace sector. A significant and growing percentage of these companies use GF AgieCharmilles 5-axis and/or EDM machine tools to achieve the part accuracies and repeatabilities, and surface finishes demanded by their customers. Aerospace applications can test even the most advanced machine tools. But GF AgieCharmilles machine tool technologies pass every test with flying colours. Milling tough materials Aerospace components are often made from hard-to-machine materials (Titanium, Titanium Alloys, Inconels, Waspalloy, and other exotics), which put machining centres through their paces. GF AgieCharmilles 5-axis machines with their advanced spindle technology, direct-drive rotary torque tables, integrated automation and SMART technology software deliver: high productivity improved cycle times reduced lead times increased quality greater process reliability reduced operational running costs. Cutting complex geometries With a trend towards requiring parts with ever more complex geometries, GF AgieCharmilles EDM technology innovations are the ideal solution for many aerospace applications. Fast and reliable, GF AgieCharmilles wire and die-sink EDM machines provide manufacturers with high levels of productivity, increased part accuracies and dramatic cost efficiencies when machining intricate and complex aerospace components. In this Flight Pack brochure a number of specific high-precision, complex aerospace parts and components manufactured by our customers are featured.

4 flightpack Technology zone: aerospace applications Impeller (Ground Power Generation Unit): Simultaneous 5-axis milling Material: ALUMINIUM ALLOY Technology used: HPM 800U (5-AXIS MACHINING CENTRE) significant cycle time reduction substantial improvement in part accuracy (due to machining part in 1 operation) reduction in work-holding and work-fixturing reduction in delivery times Machining time prior to GFAC technology: 12 hours 44 minutes Machining time using HPM 800U: 6 hours 24 minutes Light Alloy Support: positional 5-axis milling Material: TITANIUM Technology used: HSM 600U (5-AXIS MACHINING CENTRE) significant cycle time reduction - 6 operations reduced to 2 operations substantial improvement in geometrical part accuracy and part tolerances reduction in work-holding and work-fixturing resources and costs reduction in delivery times reduction in cost per part Machining time prior to GFAC technology: 1 hour 37 minutes Machining time using HSM 600U: 42 minutes

5 Navigation Electronic Circuitry Housing: positional 5-axis milling Material: TITANIUM Technology used: HSM 400U (5-AXIS MACHINING CENTRE) improved part accuracies machining operations reduced from 6 to 2 (faster production) reduction in work-holding and work-fixturing, and work-handling reduction in delivery times Machining time prior to GFAC technology: 52 minutes Machining time using HSM 400U: 36 minutes Aircraft Fuel System: Simultaneous and positional 5-axis milling Material: ALUMINIUM ALLOY Technology used: HSM 600U PRODMOD (5-AXIS MACHINING CENTRE) significant cycle time reduction (29 operations down to just 5 operations) substantial improvement in accuracies - (specifically asymmetric bore alignments) improved surface finish reduction in work-holding and work-fixturing reduction in delivery times Machining time prior to GFAC technology: 23 hours 6 minutes Machining time using HSM 600U: 7 hours 24 minutes

6 flightpack Technology zone: aerospace applications (cont.) Microwave Electrical Circuit Box: positional 5-axis milling Material: ALUMINIUM Technology used: UCP 600 VARIO (5-AXIS MACHINING CENTRE) reduction in cycle time (6 operations reduced to 2 operations) reduced work-holding costs improved accuracies and repeatability's faster volume production (via integrated pallet changers) Machining time prior to GFAC technology: 1 hour 10 minutes Machining time using UCP 600 Vario: 37 minutes Drop Tank Cover Plate: positional 5-axis milling Material: ALUMINIUM Technology used: HPM 600U (5-AXIS MACHINING CENTRE) Benefit from using GFAC Technology: reduced cycle times fewer set-ups fewer tools required reduced cost per part Machining time prior to GFAC technology: 1 hour 1 minute Machining time using HPM 600U: 21 minutes

7 Bearing Active Pre-Load System: Wire EDM Material: TITANIUM Technology used: FI 440CCS (WIRE EDM MACHINE) re-cast layer reduced to 6µm elimination of oxidation accuracy of intricate features improved to +/- 5 microns surface finish of Ra 0.2µm achieved cheaper brass wire used for rough cutting Machining time prior to GFAC technology: 42 hours 30 minutes Machining time using FI 440 CCS: 34 hours Exit Valve Guide: Die-sink EDM Material: INCONEL 625 Technology used: FO 350 SP (DIE-SINK EDM MACHINE) homogeneous and consistent surface finish: VDI 27 zero electrode wear: IQ Technology reduced electrode manufacturing costs: IQ Technology fast removal rates simple and straightforward set-ups, technology and parameter selection high acceleration and fast Z-axis movement deliver increased productivity Machining time prior to GFAC technology: 67 hours (including manufacture of electrodes) Machining time using FO 350 SP: 56 hours and produced electrode savings of 80%

8 Contact Agie Charmilles Ltd North View Coventry CV2 2SJ United Kingdom Tel. +44 (0) Fax +44 (0) Website