CUT200 Dedicated

CUT200 DedicatedGF Machining SolutionsEric Ostini

CUT 200 Dedicated

GF MS NSC NOLA 2014

Soaring Travel Demand:Increased globalizationGrowing GDPLiberalization of air transportDecreasing travel prices

Ambitious targets to:Reduce hazardous emissionsBoost fuel efficiencyReduce aircraft weight.

By 2020, aircraft are to:Burn 50% less fuelEmit 50% less carbon dioxide (CO2)Emit 80% less mono-nitrogen oxidesReduce noise emissions by half

As a result, the aerospace value chain faces a constrained capacity scenario as production is expected to increase 45 percent (up to 70 percent) in the next two years.Immense Challenges in AerospaceGF MS NSC NOLA 2014

BroachingWEDMSlots / Part147147Time / Part360 min1720 min# of M/C15CAPEX Investment (USD)M/C Cost4,078,0002,600,000Footprint300,000100,000Total4,378,0002,700,000Running Costs per Slot (USD)Tooling18.3519.03Consumables28.005.10Power0.073.60Total46.4227.73

WEDM versus Broaching

Comparing machining costs associated with fir-tree slot production in LP turbine engines using WEDM and broaching

Preliminary cost analysis shows that WEDM is approximately 40% cheaper compared to broaching while maintaining similar productivity levels. In such a case, 5 units of WEDM are needed to reach the same productivity of 1 broaching machine.

GF MS NSC NOLA 2014

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CUT 200 Dedicated

Removal of work table for increased flexibilityExpanded work tank for improved dielectric thermo-stabilizationA-Axis (swivel) for fir-tree slot taper angleC-Axis (rotary) for fir-tree slot positioningGF MS NSC NOLA 2014

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CUT 200 Dedicated

Optimal design of lower head to avoid collisionIncreased number of filters for consistent water qualityWire remains straight for improved speeds & process stabilizationSlug-evacuation container to catch falling slugs

GF MS NSC NOLA 2014

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CUT 200 Dedicated

Innovative EDM generator with enhanced performanceDedicated Inconel technology to eliminate recast layer & micro-cracksRelocation of discharge circuit for increased machining speedWith eTracking module, fully traceable process

GF MS NSC NOLA 2014

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CUT 200 Dedicated

Direct connection of discharge circuit cablesDynamic fixture offset compensation function for disk concentricityAutomatic drop-door on work tank sideExternal automation (robot) kit available

GF MS NSC NOLA 2014

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CUT 200 Dedicated

AC CUT human machine interfaceErgonomic design for enhanced user-friendlinessEMC norm compliantSmall foot print for additional cost savings

GF MS NSC NOLA 2014

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CUT 200 Dedicated -In process inspection

Probe System provides Automate setup PWC setup time went from 20 minutes minimum to 5 minutesCheck flatness in X and YCheck if disk is on center of B axisCheck Z heightCheck A axis angle

Reduced fixture tolerances With probe data the machine can compensate for X,Y shift.

Removable with robot

Adds extra layer of validation to the process. This information is recorded in eTracking.

GF MS NSC NOLA 2014

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4.81m

3.26m

2.66m

1.86m

Not Visible At 500X

3.21m

1.40m

1.01m

0.90m

Not Visible At 500XSurface IntegrityNo Visible Recast Layer

Within Aerospace, EDM technology has typically been considered a taboo technology due to limitations within spark generators of the past, leaving recast layers of >3um.

Advances in GFAC generator technology ensure surface integrity in both Titanium and Inconel, with no visible recast layer or micro cracks after 4 trim cuts.

No blue discoloration in Titanium.

Main CutTrim Cut 1Trim Cut 2Trim Cut 3Trim Cut 4--------------------------------------------------TitaniumInconel

GF MS NSC NOLA 2014

Traceability GFAC Only

A dedicated software to monitor each machining process in detail and ensure traceability, which is essential in Aerospace .Real-time dashboard to monitor the entire workshop.Preventative maintenance confirmation and alert function.This Includes:Monitoring of machining data and comparing to reference valuesMonitoring of consumable parts and control itemsCheck lists before machiningTraceability of data during machiningMonitoring of machine status in shopGF MS NSC NOLA 2014

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Traceability GFAC Only

Cutting SpeedUpper Injection [bar]Lower Injection [bar]

Upper LimitActualLower Limit

Upper LimitActualLower Limit

Upper LimitActualLower LimitGF MS NSC NOLA 2014

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A dedicated package adapted to the specific needs within Aerospace.Guaranteed repeatability and traceability of machining process.Conducted according to Nadcap AC7116.

This Includes:Preventive MaintenanceRegular inspection & adjustmentQualified recommendationsGenerator CalibrationEDM parameter controlSpark shape acquisitionIn-depth data analysis and reportingCertified TrainingVerification of acquired knowledgeNADCAP Certification Support GF MS OnlyGF MS NSC NOLA 2014

CUT 200 Dedicated - SummaryKey Characteristics:Optimal speed & process stabilityWire straight at all timesRelocation of discharge circuitDedicated Inconel techologyA-Axis (swivel) and C-Axis (rotary)Increased work tankThermo-stabilizedeTracking (traceability) functionAutomation ready

Benefits:No limitations on material hardnessSurface integrity preservedIncreased profile accuracyImproved surface contact w/ bladeNarrow slots capable fuel %Geometries independent of toolingDeburring operations not neededHigh cost saving vs broachingFully traceable & repeatable process

GF MS NSC NOLA 2014

GF AgieCharmillesGF MS NSC NOLA 2014

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Thank youMaster ScheduleGF MS NSC NOLA 2014