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GF AgieCharmilles aerospace case studies

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Page 1: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

GF AgieCharmilles aerospace case studies

Page 2: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Making a difference in the Aerospace sectorflightpack

Page 3: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Aerospace manufacturing

encompasses a wide variety of parts,

diverse in their shape, size, design

and material used.

To meet the complex needs of the

industry, GF AgieCharmilles offers a

comprehensive portfolio of class-

leading high-speed and high-

performance 5-axis machining

centres and market-leading wire and

spark erosion EDM machines.

If you are in involved in manufacturing

precision components for the

aerospace sector, or if you are looking

to make your mark in aerospace

manufacture, you need to get

GF AgieCharmilles technology on

your side.

In this Flight Pack brochure you can

read more about GF AgieCharmilles

customers that have done just that.

In the following pages the spotlight is

focused on six GF AgieCharmilles

customers who are all involved in

manufacturing high-precision,

complex parts for the aerospace

sector.

Three of these companies have

recently invested in our 5-axis

machine tool technologies, the

remaining three in our EDM

machines.

All six companies have significantly

improved their productivity,

performance and profitability since

investing in GF AgieCharmilles, and

are firm advocates of our

technologies.

The remaining pages will tell you

more.

FACTAs well as supplying market-leading

technologies, GF AgieCharmilles also

provides a range of first-class

customer-focused services: maintenance

& servicing, wear parts, consumables,

training and System 3R workholding and

tooling solutions.

Page 4: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Taking off with 5-axis milling technology!

Solihull-based precision manufacturingsubcontract specialist - MidlandPrecision Engineering Co Ltd (MPE),has recently invested in a Mikron HSM600U ProdMod 5-axis machining centrefrom GF AgieCharmilles.

The machine, supplied with a 36,000rpmspindle (HSK-E50 interface), 7-stationintegrated workpiece pallet changer, 170-position ATC, through-spindle-coolant and integrated tool breakageand tool measurement system – wasinstalled at MPE’s facility in Shirley inDecember 2008.

The catalyst behind MPE’s investment inthe HSM 600U ProdMod machine wasthe Company’s successful tender tomanufacture high-precision, complexfuel system parts for a new andinnovative Jet aircraft prototype.

Says Adam Ormandy, Managing Directorat MPE:

‘The fuel system, part of a majorassembly, is characterised by itscomplexity (i.e. a multitude ofasymmetrically-positioned and differentsized diameter bores).

‘The fuel system was a prototype – and as such we knew that there would be anumber of design modifications andreiterations that we would need tomanage.

‘To ensure we could handle thesechanges and meet the deliverydeadlines required, as well as achievingthe part accuracy and surface finishrequirements - we knew we neededadvanced 5-axis machine tooltechnology on our side.

Joining the jet set!

Business: PRECISION MANUFACTURER

GF AgieCharmilles technology:

5-AXIS MILLING

Most recent investment:

HSM 600U PRODMOD

Company: MIDLAND PRECISION ENGINEERING CO LTD

flightpack

Page 5: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

‘As a consequence we began our searchfor the optimum machine tool solution.’

The decision to invest in the Mikronmachine was made for a number ofreasons.

Continues Adam Ormandy:

‘It was important that the machine hadintegrated APC capability, so that wecould load and set-up jobs on the ‘free’pallets whilst the machine was stillrunning. It was also equally importantthat the machine had a good-sized toolchanger (ATC) to enable suchcontinuous machining to occur – and togive us a high degree of manufacturingflexibility and autonomy.’

The HSM 600U ProdMod’s small,compact footprint was also a keyconsideration.

Other important issues affectingmachine selection included the high-speed spindle capability of the HSM600U ProdMod, with its coolant-through-spindle option, and tool breakand measurement system for increasedprocess reliability.

But it wasn’t just the HSM 600UProdMod’s advanced features andoptions that sealed the deal.

Continues Adam Ormandy;

‘The Jet aircraft project is prestigious

and of critical importance to MPE.That’s why, in addition to an advanced 5-axis machine tool, we were alsolooking for expert technical andapplications help and assistance to beprovided by the machine toolmanufacturer/supplier as well.

‘This technical support was, as it turnedout, extremely critical. Not only did thecollaborative approach help us agreethe machining processes to beemployed – but also established thebest CAD/CAM solution (Delcam’sPowerMill and PowerShape), and helpedsolve the fixturing and workholdingchallenges that confronted us too.’

‘That’s how and why the Mikronmachine from GF AgieCharmilles wasselected.’

MPE is not your typical precisionmanufacturing subcontractor.

As well as recently investing in 5-axismachine tool technology, the Companyhas also made significant investment indeveloping and improving itsmanufacturing operations across theboard.

These include strengthening its grindingcapabilities, purchasing specific testingand measurement equipment (forroundness and cylindricity etc.), creatinglean and customer-focusedmanufacturing cells, installingtemperature-controlled productionzones and extending its secondaryoperations and services (assembly,pressure testing, laser marking,vacuum packaging etc).

Continues Adam Ormandy:

‘Investment is critical to our continuedgrowth and success.

‘We have built a reputation in themarket and with our customers forinnovation, technical excellence andworld-class service. We can be reliedupon to deliver outstanding results andsolutions when faced with even themost difficult and complicated ofchallenges. Our ambition always is to bethe best we can possibly be – and tobecome our customers’ partner ofchoice.’

These ambitions have been realisedwith the on-going Jet aircraft projectwith MPE receiving a ‘SpecialRecognition Award: Aero EngineControls’ for its work. Similar accoladesand recognition have also been receivedfrom MPE’s other aero-engine (fuelsystems) and medical (scientificinstrumentation) customers.

The HSM 600U PRODMOD is equipped with anintegrated workpiece pallet changer for highproductivity and manufacturing flexibility.

The HSM 600U PRODMOD’s tool changer can hold75, 120, 170 or 220 tools.

Page 6: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

North Somerset-based precisionmanufacturing specialist - A.I.M Ltd –has recently invested in a new Mikronhigh-performance 5-axis millingmachine from GF AgieCharmilles.

The machine, a UCP 600 Vario is beingused to manufacture high-precisioncomplex components used within theaerospace sector.

The UCP 600 ‘Vario’ was purchasedprimarily to meet the demands of a newlong-term contract secured by thecompany to manufacture high-precision(and high-value) aerospace componentparts.

These parts, made from solid aluminium,had been previously manufactured byA.I.M. on the company’s existingmachines.

Whilst this arrangement had beensatisfactory in terms of meetingcustomer part quality and delivery timerequirements – the new contract was formore parts and therefore demandedmanufacturing output and productivity tobe increased.

Remembers Rob Kendall, A.I.M’sManaging Director:

‘The nature of the component, and thequantities required, pointed us in thedirection of a 5-axis simultaneousmachining solution.’

A.I.M. is no stranger to 5-axis machiningand had, in 2000, invested in its first 5-axis machine – a Mikron UCP 600 – astandard 5-axis machine.

Continues Rob Kendall:

‘Initially we were considering investing ina second UCP 600 machine to cope withthe new order – but having contacted GF AgieCharmilles we began discussingthe possibility of a more production-oriented 5-axis machine equipped withintegrated automation’.

The ‘Vario’ 5-axis machine is designed forproduction and is equipped with anintegrated 7-station APC. The machine’sconfiguration enables customers tobenefit from all the advantages of 5-axis‘one-hit’ machining i.e. reduced set-ups;reduced workholding; improved partquality; improved cycle times etc – butwith the added advantage of being able torun unattended and unmanned.

For A.I.M. this appeared to be the perfectsolution.

However, to fully capitalise on themachine’s capabilities and to ensuremaximum productivity meant thecompany would need to develop new andinnovative workholding and fixturing.

Continues Rob Kendall:

‘Previously we used to manufacture theaerospace part (one at a time) by settingthe job up on the machine’s table andmachining the outer face. The job wasthen transferred to another 4-axismachine to complete the inside face ofthe component.

‘With the arrival of the Vario with its APC– we designed a cube (4-face)workholding solution that allows us tomachine 4 parts per pallet in one-hit. Wenow also machine the inside face of thepart on the ‘Vario’ as well using a similarcube workholding solution.’

The productivity gains from thisarrangement are exceptional – moreparts produced (up to 160 parts permonth), in less time and to better quality.Prior to the ‘Vario’ and cube workholdingsolution one part was produced every 40minutes – now 4 parts are produced every hour!

Taking off with 5-axis milling technology!

Company: A.I.M LTDA.I.M – to win!

flightpack

Business: PRECISION MANUFACTURER

GF AgieCharmilles technology:

5-AXIS MILLING

Most recent investment: UCP 600 VARIO

Page 7: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Leading precision engineeringsubcontractor Arden Precision Ltd,Solihull, has recently invested in asecond HPM 1350U high-performance5-axis milling machine from GF AgieCharmilles.

The new machine was installed at thecompany’s Solihull facility in the Springof 2008 and is being used tomanufacture high-precision complex and critical-performance partspredominantly for the aerospacesector…a sector that today accounts forover 90% of the company’s annualturnover.

Arden Precision Ltd, first established in1980, has developed successfulpartnership relationships with manyleading civil and military aerospaceOEMs and First and Second Tiersuppliers, and has built a strongreputation in the sector for its quality,reliability and cost-competitiveness.

The company’s latest 5-axis machinetool investment has enabled ArdenPrecision to improve its performance inthese critical supply-chain areas stillfurther.

The aerospace parts and kitsmanufactured by Arden Precision on itsnew 5-axis machine vary in size,complexity, material and volume.

Typically parts are made fromAluminium, Stainless, Titanium andSuper Alloys, and are required in low-to-medium batch sizes.

Parts are machined on the HPM 1350Ufrom castings or from solid with parttolerances on certain features (i.e.internal radii and small diameter bores)being as tight as 0.01mm. Similarlyexacting surface finish standards (Ra 0.4µm – Ra 0.8µm) are alsofrequently required.

The company uses the new HPM 1350Umachine for both 3+2 (positional) andfull 5-axis simultaneous machining –depending on the application inquestion.

Says Ian Gleed, Senior ManufacturingEngineer at Arden Precision:

‘Our new 5-axis machine tool capabilitygives us significant productivity gainsand manufacturing flexibility. Prior toinvesting in the Mikron machines – we

relied on our 3- and 4-axis machines forall our milling requirements.

‘Whilst these machines could be reliedupon to deliver, we knew we werespending significant time and resourceson frequent job set-ups, workholdingand fixturing, and operator intervention.

‘Through our 5-axis machine toolinvestments, we have improved ourperformance and competitivenessacross the board.

‘Machine cycle times have been reduced(by up to as much as 30%); parts can bemachined in a single set-up and, as aconsequence we have improvedmachine tool utilisation, freed-upmachine tool capacity and removedproduction bottle-necks as aconsequence.’

Company: ARDEN PRECISION LTD

Big stuff in theAerospace sector.

Business: PRECISION MANUFACTURER

GF AgieCharmilles technology:

5-AXIS MILLING

Most recent investment: HPM 1350U

Page 8: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Company: CAMCRAFT LTDPrecision toolmaking specialist –Camcraft Ltd – has recently invested in 3 new EDM machines from GF AgieCharmilles.

The machines (2 x FO 550S sparkerosion machines and 1 x FI 640CCCleanCut wire machine) were installedat Camcraft’s facility in Bishops Frome,Worcestershire in 2009 and are beingused to manufacture high-precisioncomplex mould tools and inserts for gasturbines used in the land based powergeneration and aerospace (aero-engine)sectors.

The 3 machines replace older, lesssophisticated EDM technology thatCamcraft had at its disposal and wereselected for their size (generousworking envelopes to handle large partsand/or to handle multiple, smaller jobs);their machining performance (highaccuracy, superior surface finishes, and

optimum removal rates and cuttingspeeds), and their autonomy.

Says Steve Pearson, Managing Directorat Camcraft:

‘The mould tools and inserts wemanufacture are incredibly complex.They are characterised by their accuracyand intricacy (i.e. delicate and hard-to-machine details and features such asthin walls, tight radii etc.), and by theirhigh value.

‘As a consequence we need access tothe most advanced and most productivetechnologies to help us manufacturetools to the highest quality... to meet thetight delivery times we work to...and tohelp us control our costs. ‘

The machines

The FI 640CC (CleanCut) machine isequipped with a high-performance

New wire and die-sink EDM machinesfor leading mould tool manufacturer.

Business: PRECISION MANUFACTURER

GF AgieCharmilles technology:

WIRE AND DIE-SINK EDM

Most recent investments: FO 550S & FI 640CC

flightpack Taking off with EDM technology!

Page 9: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

digital generator that combines speed(500mm2/min) with excellent machiningresults (i.e. elimination of the re-castlayer and surface finish realisation of Ra 0.2µm).The machine also featuresautomatic wire thread capability (forlong, uninterrupted running), integratedcollision protection (for greater processreliability) and linear glass scales forguaranteed accuracy.

The FO 550S die-sink machines (X-, Y- and Z-travels of 600mm x 400 x450mm respectively), can handle largeworkpieces (up to 1600kg). The machineis equally adept with Graphite as well asCopper electrodes - and workpiecesurface finishes of Ra 0.1µm can beachieved.

Camcraft mould tools (aerospace)

Modern aircraft engines need to satisfyseveral (often competing) requirements.They must be:

• Lightweight: heavy engines

decrease the amount of excess power

available.

• Small and streamlined: large

engines, with substantial surface

areas, create too much drag and

waste fuel and reduce power output.

• Powerful: to overcome the weight

and drag of the aircraft.

• Reliable: aircraft engines operate

at high temperatures, pressures,

and speeds - and therefore need to

operate reliably and safely under

all these conditions.

• Repairable: to keep the cost of

replacement down.

• Efficient: to reduce emissions and

environmental impact.

Constant research and development inaero-engine design, materials scienceand methods of manufacture aretherefore the nature of the game – andit is in this environment of change andconstant refinement where Camcraftoperates.

Camcraft mould tools are used in theinvestment casting (lost wax) process.

The Company works closely with itsfoundry customers (based in the UK andoverseas), to design, manufacture high-quality tools which are used to producea range of performance-critical aero-engine parts such as turbine blades andvanes, as well as a variety of enginemountings and housings.

Investment casting of new, super enginealloy materials (i.e. Titanium Alloys)enables the development of moreintricate and innovative designs thatimprove engine performance and delivergreater engine fuel efficiencies. And,because aero-engines run at highertemperatures they must be cooled byever more complex cooling solutionswhich must also be accommodated inan aero-engine’s design andmanufacture.

Camcraft mould tools start life fromdrawings and/or models. The mouldtools and inserts are machined using GF AgieCharmilles technology fromwhich the wax patterns (expendable)and ceramic cores are made.

To ensure that the patterns and coresproduce the desired finished castingresult it is likely that a number of designmodifications will occur to the mouldtool and a number of different iterationsmade to the patterns and cores as aconsequence.

The process can be long and involved –but Camcraft, through its experience

and know-how (including access toadvanced machine tool technologies),can be relied upon to deliver on-time,in-time and in-budget solutions.

TECHNOLOGY UPDATE

GF AgieCharmilles in 2010introduced its revolutionary andaward winning IQ technology(zero electrode wear) on all of itshigh-performance die-sink EDMmachines.

Page 10: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

flightpack Taking off with EDM technology!

High accuracy and stringent surfacefinish and surface integrityrequirements when machining hardand difficult-to-machine materialsprovides catalyst for latest EDMinvestment.

Dudley-based precision EDMmanufacturing subcontract specialistElectro-Discharge Ltd has recentlyinvested in a new, high-performanceCNC wire EDM machine from GF AgieCharmilles.

The machine, a FI 440CCS, equippedwith GF AgieCharmilles' CleanCuttechnology, was installed at theCompany's facility in Netherton inAugust 2009, and is being used tomanufacture high-precision, complexparts predominantly for the aerospace(aero-engine), oil/gas, satellite andpower generation sectors.

In any given week/month Electro-Discharge can be required tomanufacture a plethora of differentprecision parts. Mainly required in smallbatches (sometimes prototypes and

one-offs), and always to high quality andtight delivery times – Electro-Dischargeoperates 24/7, and demands a greatdeal from its in-house EDM capabilities.

The new FI 440CCS was specificallyselected by Electro-Discharge tomachine complex Titanium andTitanium Alloy components, and toachieve the high accuracies (+/- 10microns) and exacting surface finishrequirements (Ra 0.1µm) demanded bythe Company’s customers.

Says Rupin Vadera, General Manager atElectro-Discharge:

‘We already had significant EDMcapability (11 x CNC wire; 9 x CNC die-sink; 1 x fast hole drill), and sinceour re-location from Coventry to Dudleyin 2000 we have invested in a number ofstate-of-the-art EDM machines toimprove our productivity, increase ourcompetitiveness and help build ourmarket-leading position.

‘The FI 440CCS, with its integratedCleanCut digital generator; automaticand fast wire thread (AWT) capability

and Integrated Collision Protection, andability to use all types of wire anddifferent wire diameters (0.33mm –0.07mm), ticked all the right boxes forour immediate and futurerequirements.’

Electro-Discharge is increasinglyinvolved in manufacturing Titanium andTitanium Alloy critical-performancecomponents for the oil/gas andaerospace (aero-engine) industries.

It is the FI 440CCS’ ability to machineTitanium (without the creation of the re-cast layer or micro-cracking) thathas enabled GF AgieCharmillesmachines equipped with CleanCuttechnology to meet, for example, theparticularly stringent NADCAP qualityrequirements, and those companies thatare NADCAP accredited.

Continues Rupin Vadera:

‘We provide our aerospace customerswith a NADCAP accredited service(AS7116, AS9100 REV: B, ISO 9001-2008and Rolls-Royce SABRe9000), so theinvestment in EDM technology thatcomplied with NADCAP requirementsmade sense.’

Company: ELECTRO-DISCHARGE LTD

Business: PRECISION MANUFACTURER

GF AgieCharmilles technology: WIRE EDM

Most recent investment: FI 440CCS

Fit for purpose!

Page 11: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Company: PS MARSDEN LTD

Business: PRECISION MANUFACTURER

GF AgieCharmilles technology: WIRE EDM

Most recent investment: FI 640CCS

Nottingham-based precisionmanufacturing subcontract specialist -PS Marsden Ltd - has recently investedin a high-performance wire EDMmachine tool supplied by GF AgieCharmilles.

The machine, a FI 640CCS equipped withGF AgieCharmilles’ CleanCut digitalgenerator technology, was installed atthe Company’s facility in July 2010 and isbeing used to manufacture high-precision, complex parts for theaerospace, defence, marine and powergeneration (land-based turbines andnuclear) sectors.

PS Marsden, as well as manufacturing arange of different production parts andassemblies for these sectors, is alsoheavily involved in a number of on-goingresearch and development (materialsscience) projects with a number of blue-chip aero-engine and gas turbine OEM’s,and leading research organisations andinstitutions...producing high-precisionspecimens for testing and analysis.

These test pieces, machined from arange of “difficult” materials - i.e.Nickel-based Super Alloys Waspalloy,Inconel, Nimonics, Titanium andTitanium Alloys (including TiMMC and

Single Crystal Alloys such as CMSX-4),are required by PS Marsden’s customersto analyse the every-day effects of heat,stress, fatigue, wear etc., onperformance-critical components.

Says Simon Marsden, General Managerat PS Marsden:

‘We use our EDM machines to cutprecise test pieces and specimens. TheEDM process, unlike conventionalmachining methods, does not deform,add further stresses to or alter theproperties of the required ‘machined’test specimen. This means thatsubsequent analysis of the specimens isnot affected or compromised by themachining process...and that in turnleads to more reliable, valid andconsistent test results.’

The use of EDM technology in aero-engine and turbine research anddevelopment demonstrates the quantumleaps advanced EDM technology hasachieved in recent years. Issues such asthe creation of the re-cast layer andpotential micro-cracking and surfacedegradation in the HAZ (Heat AffectedZone) have been resolved thanks to theCleanCut generator technologydeveloped by GF AgieCharmilles.

PS Marsden’s decision to invest in the FI 640CCS machine was not only basedon the machine’s CleanCut technology.

Continues Simon Marsden:

‘The size of the machine was alsoimportant and the fact that it can handlelarge workpieces was a keyconsideration. Some of the specimenswe are asked to produce (i.e. sectionsfrom aero-engine rings) are large andheavy – so machine size and stability areclearly critical to us.

‘But, having said that, it was alsoimportant that the machine could deliverexceptional accuracy too as the parts wemanufacture are machined to closetolerances (typically +/- 10 microns).’

Other issues affecting the purchasedecision were the machine’s cuttingspeed (500mm2/min), surface finishpotential (Ra 0.2µm) and its reliabilityand efficiency achieved via the FI 640CCS’ Automatic Wire Thread(AWT); Integrated Collision Protection(ICP); ECONOTEC technology.

At the cutting edge!

Page 12: GF AgieCharmilles aerospace case studies - Georg Fischer · innovative Jet aircraft prototype. ... from MPE’s other aero-engine (fuel systems) ... PRECISION MANUFACTURER GF AgieCharmilles

Contact

Agie Charmilles Ltd

North View

Coventry CV2 2SJ

United Kingdom

Tel. +44 (0)2476 538666

Fax +44 (0)2476 530023

Email [email protected]

Website www.gfac.com/uk