Al-Li alloys’ high strength, low density, high stiffness, damage tolerance, corrosion resistance, and weld-friendly nature make it a better choice than traditional aluminums in commercial jetliner airframes. Workers don’t have to wait for connections to be reattached before they can use their tools. (Here non-conductive fiberglass plays a role.). The industry continues to march toward components of lighter weights, increased strengths, and greater heat and corrosion resistance. Composite materials are made of two materials, one acting as the matrix and the other as the reinforcement material. It has two tool turrets, a main spindle with C-axis and 42mm bar capacity (7,000rpm, maximum 29kW and 65Nm), and a swivel counter spindle with C-axis for extensive rear end machining. XD technology, which stands for extremely deep, enables holes to be drilled in one operation without pecking in steel, cast iron, or non-ferrous metals. Composite materials are widely used in the Aircraft Industry and have allowed engineers to overcome obstacles that have been met when using the materials individually. Complex parts such as jet engines, landing gear, and galleys will all be built with automation and tools powered by the AGVs’ inductive power transfer source. The contouring head can produce features such as valve seats, seal faces, O-ring grooves, straight/tapered threads, chamfers, and external profiles. The head accommodates tools up to 600mm long and weighing up to 18kg. IMTS 2014 booth #S-8021. In addition to time and labor savings from eliminating roots and vines, inductively powered AGVs support higher production quantities by: Eliminating battery and power management from the assembly process: As production volumes grow, demand on batteries increases and their life decreases. FEMCO’s IMTS 2014 booth will feature the HL-55/2000, a dynamic, heavy-duty boxway CNC lathe that will be integrated to a Fanuc robot emulating a production wheel turning cell. The engine is the most complex element of an aircraft, houses the most individual components, and ultimately determines fuel efficiency. IMTS 2014 booth #S-8136. Todd Johnson has worked on the development, commercialization, and sales sides of the composites industry since 2004. Specifications An antitear strip is required for aircraft that have a never-exceed speed in excess of 250 miles per hour. Since 1987, the use of composites in aerospace has doubled every five years, and new composites regularly appear. As the new kid on the block, it was considered to be lightweight, inexpensive, and state-of-the-art. A touch probe can be used in the boring spindle or on an auxiliary arm for in-process or post-process measurement of part features machined by either spindle. Changes to the line path are managed with software and controls and can be completed before the line path or processes are changed. In addition, the HL-35DMSY multi-axis CNC lathe equipped with a sub-spindle, Y-axis, C-axis, and a 23-station, live tool dual-disk turret will demonstrate its ability to machine complex parts efficiently and accurately. Major structural components that need to be stronger and lighter than the previously used stainless steel alloys are perfect application points for this titanium alloy. www.walter-tools.com/us www.femcousa.com New cloud capabilities of ESPRIT Cloud-Enabled CAM software enable programmers to select tools based on part features in minutes, without flipping through catalogues to find tooling. This class of materials is, in general, very large; it includes polymer matrix, metal matrix, and ceramic matrix composites (CMCs), as well as continuous and discontinuous fibers. Rigid, accurate, and thermally stable, the ST-55 is a heavy-duty, large-bore turning center with twin-chuck capability, high-torque spindle, and 12.5" (318mm) diameter through-bore. The 3D laser scanner precisely recognizes the components for picking. The spindle can be geared down for extra torque. Monocoque ('single-shell') molded structures deliver higher strength at a much lower weight. Walter will also be highlighting other technologies, such as counterboring and precision boring tools, through-hole taps, cutting fluids, and coolants. Maximum part height is 730mm, and longest tool is 500mm (19.6"). Beyond the day-to-day operating costs, the aircraft maintenance programs can be simplified by component count reduction and corrosion reduction. It automatically adapts to the surface color or reflectivity of materials such as machined, cast, stamped, or forged metals, plastics, and carbon fiber. To be clear, these new metals aren’t always new, some having been available for decades. Engineering teams at Virginia Polytechnic Institute and State University in Blacksburg, Va.; Purdue University in W. Lafayette, Ind. DP Technology Corp. An optional guide pot automatically guides the honing tool straight into the bore. The use of composite materials in commercial transport aircraft is attractive because reduced airframe weight enables better fuel economy and therefore lowers operating costs. “The UAS test sites will help us identify operational goals as well as safety issues we must consider when expanding the use of unmanned aircraft into our airspace,” says FAA Administrator Michael Huerta. ; there are others, such as boron-reinforced (itself a composite formed on a tungsten core). the extent of the damage is difficult to determine. Also, compared to other industries, aerospace component orders often consist of short run quantities and long lead times, rendering scheduling for productivity, throughput, and profitability difficult. Creating a safer work environment: Tuggers and cables being dragged along with the aircraft can cause trip and collision hazards, which increase as the line accelerates. In an experimental program, Boeing successfully used 1,500 composite parts to replace 11,000 metal components in a helicopter. THe material that strengthen the existing material when adding to it are called reinforced material. They move quietly on a smooth surface, and carry their cables with them to reduce trip hazards. The team estimated the total cost of the system at $199.5 million for production plus 10 years of operation and maintenance. The rotary table rotates by high-precision bearing and low-friction surfaces for smaller load capacities and hydrostatic bearings for larger load capacities. IMTS 2014 booth #E-3210. The AGVs will power the tools, automate the assembly process, interact with the MES and other production systems to communicate work instructions and measure quality, and finally converge into the aircraft’s final assembly location where they will position and automate their installation into the plane. Hexagon Metrology Fiber-reinforced polyesters can be processed by many methods. The matrix has a lower density, stiffness and strength than the reinforcement material, and as a result the reinforcement of the matrix, to provide the majority of the strength and stiffness of a composite is accomplished by the fibres. ThoughtCo, Feb. 16, 2021, thoughtco.com/composites-in-aerospace-820418. Polymer-matrix composites (PMCs) are the lightest of the three types of composite materials under study in the HITEMP program. There are five categories of carbon fibers generally used in composites; low modulus, standard modulus, intermediate modulus, high modulus and ultra-high modulus. (2021, February 16). The glass fiber is usually flattened into a sheet, randomly arranged or woven into a fabric. With up to 5,000 lb of precision clamping force, the Chameleon provides more clamping options than previous standard vises. Integration into manufacturing execution and other production systems is necessary to ensure that automated work instructions, sequencing, error proofing, and traceability are incorporated into production. Standard aerospace aluminums – 6061, 7050, and 7075 – and traditional aerospace metals – nickel 718, titanium 6Al4V, and stainless 15-5PH – still have applications in aerospace. * Strength is greater than 5GPa due to highly aligned planes of graphite. Glass Fiber Reinforced Concrete. But the reappearing aluminum is not your father’s aluminum. Stroke motors: 1-98ft/min. The mix of materials in aerospace will continue to change in coming years with composites, freshly machineable metals, and new metals increasingly occupying the space of traditional materials. The Mega Line is a new range of solutions for heavy-duty applications with extra-large pitches. Perhaps more importantly, TiAl has the potential to improve the thrust-to-weight ratio in aircraft engines because it’s only half the weight of nickel alloys. Composites can also use metal fibres reinforcing other metals, as in metal matrix composites (MMC) or ceramic matrix composites (CMC), which includes bone (hydroxyapatite reinforced with collagen fibres), cermet (ceramic and metal) and concrete. IMTS 2014 booth #E-5202. www.unist.com A vertical design permits unobstructed chip flow and good ergonomics for setup operations. Premiering at IMTS 2014, the KB-150W horizontal boring machine meets an assortment of requirements. TLM advantages range from defining the tools, to using them in planning, to ensuring a seamless use in production, according to the company. The Puma AE is a small, hand-launched UAS that is about 4-1/2ft long and has a wingspan of 9ft. Rockford Area Aerospace Network (RAAN), a committee of the Rockford Area Economic Development Council (RAEDC), offers a forum for collaboration among local companies and institutions serving the aerospace industry. Our aircraft insulation films are used in a variety of applications on the aircraft to enhance thermal, acoustic, anti-vibration, fire-barrier, and electrical insulation properties. The installation and change process is simpler and less expensive than using chain-based conveyance or adding a fleet of battery-powered AGVs. the resin while the latter is still in the liquid (uncured) ... Types of Composite Material. They can be metallic, organic, synthetic or mineral. Component counts will decrease in favor of stronger, near-net shapes, and design will continue its close collaboration with material characteristics. This approach is being applied more and more in aerospace component design because its components have to accomplish certain loads and temperature resistances, and some materials can only accommodate so much. They reduce weight and increase fuel efficiency while being easy to handle, design, shape, and repair. They are also used in leading- and trailing-edge wing components. In general, this bodes well for composites in aerospace, which can be formed instead of machined. It provides 0.0005" part clamping repeatability. III. FEMCO Inc. Whereas an aluminum wing has a known metal fatigue lifetime, carbon fiber is much less predictable (but dramatically improving every day), but boron works well (such as in the wing of the Advanced Tactical Fighter). Materials supplied as reinforcement include roving, milled fiber, chopped strands, continuous, chopped or thermoformable mat. Like CFRPs, they can be molded to certain shapes without any extra machining, making them ideal for internal aerospace engine components, exhaust systems, and other “hot-zone” structures – even replacing the latest in HRSA metals listed earlier. CGTECH The key with triple 5-3 is to run a bit slower and optimize the tool path and coolant system to achieve a good balance of tool life and tool security. If this structure is severely damaged, the aircraft cannot fly. The process of removing and reattaching air and electrical cables – referred to as roots and vines – can take almost as long as the assembly process for each station. The advantages of this scalable automation process include increased productivity, improved machine utilization rates, reduction of the need for additional machines to achieve desired plant production volumes, and more consistent production quality. Constant pressure for greater fuel efficiency is forcing aerospace manufacturers to find ways to incorporate new and existing materials that had once been considered impractical to machine. Even though the amount of aluminum is declining in aircraft, its use is not completely disappearing. The spindle is guaranteed under normal use for up to 20,000 hours, and it minimizes thermal distortion for optimal tool performance and high surface finishes. www.fivesgroup.com Co. In such cases, Carpenter Technology Ferrium S53 steel alloy has provided mechanical properties equal to or better than conventional ultra-high-strength steels, such as 300M and SAE 4340, with the added benefit of general corrosion resistance. ; and the University of Virginia (UVA) in Charlottesville were named first- through third-place winners, respectively, of the agency’s 2013-2014 University Aeronautics Engineering Design Challenge. A fiberglass is a form of fiber-reinforced plastic where glass fiber is the reinforced plastic. In fact, aluminum is coming back, especially in cases where the move to CFRP has been cost prohibitive or unsuccessful. ESPRIT also includes time-saving upgrades in the areas of tooling automation, simulation, and shop-floor collaboration. It is 3.5" wide with a 4" jaw opening and mounts easily upright and on both sides. A 0.5" movable jaw stroke allows precise raw stock clamping with less material preparation for fast positioning in the vise jaw. The combination of matrix and reinforcement equips composite materials with much better mechanical performance than the matrix and reinforcement material alone. ; there are others, such as boron-reinforced (itself a composite formed on a tungsten core). The rear chuck area is also fully enclosed during machining, but a wide sliding door and swinging end panel provide access from the front and top, simplifying chuck installation and adjustment. These type of composite materials are Properties of Carbon Fiber * Diameter is similar to 8mm. A master control panel communicates wirelessly with the AGVs to manage flow and processes. These metals, however, are currently ceding territory to new alloys designed to improve cost and performance. The reinforcement materials are impregnated with. Most of the non-critical structural material – paneling and aesthetic interiors – now consist of even lighter-weight carbon fiber reinforced polymers (CFRPs) and honeycomb materials. GROB Systems An antitear strip is a strip of the same type of fabric as is used for covering the wings. Both models have robust 80,000psi ductile iron bodies. www.hwacheon.com Times have changed. IMTS 2014 booth #N-7018. aircraft components. Titanium 5553 (Ti-5553) is another metal that is reasonably new to aerospace, exhibiting high strength, light weight, and good corrosion resistance. But TiAl is more easily machined, exhibiting similar machinability characteristics to alpha-beta titanium, such as Ti6Al4V. It has an increased 4" wide jaw opening, with up to 5,000 lb of clamping force, and provides vertical workholding for second operation machining in the same setup. The machine’s spindle design accommodates very long tools (365mm or 14.3") with no interference. Johnson, Todd. The KB-150-W Series is a T-type boring machine for streamlined, multi-face machining of large-sized work pieces. High impact resistance - Kevlar (aramid) armor shields planes, too - for example, reducing accidental damage to the engine pylons which carry engine controls and fuel lines. With all main machine elements made of cast iron, the rigid, robust, and stable design provides for high precision. The Federal Aviation Administration (FAA) has authorized the first commercial unmanned aircraft system (UAS) operation over land. Johnson, Todd. Standard, non-CE guarding includes easily removable covers for each end of the honed part, while optional CE guarding includes a light curtain and wire mesh enclosure. Four of the six congressionally mandated test sites for UAS research are now operational. The constituent materials retain their identities in the composites and do not dissolve or otherwise merge completely into each other. Reinforcement: A strong material which gets mixed with a resin to form composite materials… Similar to heat resistance, certain composite materials such as Aramid fiber can yield high-impact resistance properties. The Federal Aviation Administration (FAA) recently granted San Diego Gas & Electric (SDG&E) a Special Airworthiness Certificate for a small Unmanned Aircraft System (UAS), allowing the utility to research, test, and train flight crews on the UAS in a sparsely populated airspace in Eastern San Diego County. Energy giant BP and UAS manufacturer AeroVironment are approved to conduct aerial surveys in the North Slope, Alaska, using an AeroVironment Puma AE. In addition, FEMCO will demonstrate the HL-25DM CNC lathe that allows for quick setups and fast tool change times. These rotation systems ensure no surface wear, meaning it is optimal for highly demanding and accurate processing. Competition exists in the military too, with continuous pressure to increase payload and range, flight performance characteristics, and 'survivability', not only of airplanes but of missiles, too. General Electric was a pioneer in this development and uses TiAl low-pressure turbine blades on its GEnx engine, the first large-scale use of this material on a commercial jet engine – in this case in the Boeing 787 Dreamliner. Once only considered for light structural pieces or cabin components, composites’ aerospace application range now reaches into true functional components – wing and fuselage skins, engines, and landing gear. Concrete is good in compression and weak in tension so, to increase the tensile strength of concrete we use reinforced material called reinforcement (steel). Both models feature a table with 225° of rotation in the A-axis and continuous 360° in B-axis. The maximum part is a 600mm cylinder (diameter: 23.6") and 500mm in height (diameter: 19.7"). Carbon fibers are frequently categorized using tensile modulus. Integrated bed frames of fine-grain meehanite castings minimize heat distortion. Chameleon is designed for tool room, knee mill applications, and use on smaller CNC machining tables. Kurt Manufacturing will introduce its expanded lineup of advanced workholding products at IMTS 2014. Haas Automation Inc. The ST-55 comes equipped with a large, hydraulically clamped 12-station bolt-on style tool turret that accepts 7.25" (184mm) split boring bar holders, as well as standard BOT toolholders. NASA has selected three winning designs to address the technological limitations of the uncrewed aerial systems (UAS) currently used to track and collect data on hurricanes. The combination of linear guiding and hydrostatic systems provides high dynamics, improving machining capability, while the highly rigid structure and boring spindle design ensures long-term machine precision. Overall, carbon fiber is the most widely used composite fiber in aerospace applications. The rigid quill spindle is mounted on large-angular-contact ball bearings, lubricated with an air-oil system. https://www.aerospacemanufacturinganddesign.com/article/amd0814-materials-aerospace-manufacturing/, Michael Standridge is an aerospace industry specialist at Sandvik Coromant and can be reached at 800.SANDVIK or, Rod Emery, vice president of Assembly Systems, RedViking, can be reached at. The VersatileLock is now available in four 8" vise models that have a 10" jaw opening. www.vargususa.com Unist Inc. Applications range from complete airplanes such as the Beech Starship to wing assemblies, helicopter rotor blades, propellers, seats, and instrument enclosures. They usually consist of a fibre-reinforced resin matrix. Machine tools builders and cutting tool manufacturers will continue to develop tools to make currently unviable materials machineable, and even practical. The materials must be at least as good a quality and of equivalent strength as those originally used by the aircraft manufacturer. cutting diameter: 36” (fits large air chucks at front and back of spindles), Spindle holes: 7.08" to 14.57" in diameter, Long bed spindle versions available from 84" to 216", 10 stations with slide travels of 140mm and 300mm in the Z-axis, Turret indexing via NC-rotary axis with a direct measuring system, Upper tool carrier equippable with up to 20 tools, 9 stations with functions identical to upper turret, Lower cross-slide serves as a swivel counter- spindle for rear-end machining, 7,000rpm (max. Developed for high production precision turning, the 42mm Traub TNK42 Fixed Headstock Automatic produces turned parts up to 250mm in length and geometrically complex workpieces in large and medium volumes. www.dptechnology.com Mechanical properties can be tailored by 'lay-up' design, with tapering thicknesses of reinforcing cloth and cloth orientation. IMTS 2014 booth #N-7400. The variances in the two materials require the use of different cutting data to obtain similar tool life. Fully tracked throughout production, an AGV can carry specific work instructions and traceability information based on the specific component or aircraft it carries. The two must be in balance, and one can’t really exist outside of the context of the other. Unlike any other industry but oil and gas, which also has high temperature, pressure, and corrosion requirements, aerospace materials themselves impact component design. Meanwhile, Alcoa is using AA2090 T83 and 2099 T8E67. The high-speed table rotates at 800rpm while compensating for uneven loads. The resin can be a vinyl ester, epoxy, or polyester, while the reinforcement might be any one of a variety of fibres, ranging from glass through carbon, boron, and a number of proprietary types. It loads tools via the machine’s automatic tool changer for faster processing without operator involvement. In addition, the line boasts a clamping system with an indented insert edge that is designed to withstand increased cutting forces during machining and prevent insert rotation. BP plans to use the system’s sensors to target maintenance activities on specific roads and infrastructure. The types have different mechanical properties and are used in different areas of aircraft construction. As a result, users can directly download a Kennametal tool assembly and use it within VERICUT software in fewer steps compared to manual configuration. The SX parting and grooving system features coolant supply through the tool. The UAS can access infrastructure that is difficult to reach for utility crews and alert them if repairs are needed. Aerospace manufacturers are a breed apart for all of these reasons. Specially developed grippers with additional axes enable collision-free access and the removal of items from the container, and subsequently allow for precise positioning of the item into a fixture or pallet. A major aircraft manufacturer is currently evaluating technology that will enable the cables to travel with the plane as it’s under production, eliminating the roots and vines that now anchor a plane to a station. This can eliminate the need for cadmium coating and the subsequent related processing. Regardless of the material, reinforcements are available in forms to serve a wide range of processes and end-product requirements. www.methodsmachine.com CGTech will demonstrate this new capability at IMTS 2014 using the latest version of VERICUT, version 7.3. Based on Hi-Tech 550, 700, and 850 horizontal turning machines, the Hi-Tech BB & BB+ turning centers’ spindle torque permits productive cutting in tough material up to 36" in diameter and more than 216" in length. The system features one to 12 outputs that can be independently configured as either MQL or air blow-off outputs. Composites in Aerospace. Each turning center is controlled by the Fanuc 0i control with Manual Guide i. Hwacheon Machinery America Forty years ago, aluminum dominated the aerospace industry. With decreased battery lives come disposal challenges as well as requirements for spare AGVs and batteries. New Tiger.tec Silver high-performance cutting material, with new positive rake 7° and 11° geometries for cast-iron machining, will also be on hand. Once the technology is tested, and if it proves effective, SDG&E may seek FAA approval to use the UASs more broadly for field inspections. CMCs are comprised of a ceramic matrix reinforced by a refractory fiber, such as silicon carbide (SiC) fiber. This new approach will use battery-free AGVs for conveyance, communication and power, and will significantly reduce costs. Each plane was built in one place, and all of the parts, tools, and operators arrived in sequence, according to plan. The competitive nature of the aircraft construction business ensures that any opportunity to reduce operating costs is explored and exploited wherever possible. In addition, a full enclosure is available. However, as volumes increase, new production technologies must be implemented. Some structural pieces, like fasteners, landing gear, and actuators, require raw strength, with lightweight properties being less of a priority. The companies will scout BP pipelines, roads, and equipment at at Prudhoe Bay, the largest oilfield in the United States. 12kW and 22.5Nm) counter spindle with 42mm spindle clearance, © 2021 GIE Media, Inc. All Rights Reserved. About the author: Michael Standridge is an aerospace industry specialist at Sandvik Coromant and can be reached at 800.SANDVIK or us.coromant@sandvik.com. We have already touched on a few, such as weight saving, but here is a full list: With ever-increasing fuel costs and environmental lobbying, commercial flying is under sustained pressure to improve performance, and weight reduction is a key factor in the equation. A typical jet built today is as little as 20% pure aluminum. IMTS 2014 booth #S-9490. It is possible to completely invert the table for upside-down machining while chips free-fall from the part. It can produce features with repeatability of ±0.005mm and accuracy of ±0.015mm. Providing a constantly available power source without the unpredictability of battery energy, these AGVs can carry and power the air compressors and electrical connections for all of the tools currently anchored to roots and vines. Air controls for MQL outputs can be controlled manually or automatically, and the air blow-off outputs assist in removing chips from the machining area. Using positional locating software, the AGVs will then transport them to the aircraft’s final assembly area, where IPT powered lifts and automation on the AGVs will move the assemblies into location to be attached to the plane. But once an operator has proper parameters set, triple 5-3 machines predictably. Weight is everything when it comes to heavier-than-air machines, and designers have striven continuously to improve lift to weight ratios since man first took to the air. The manufacturer estimates that eliminating those connections on an indexing line will reduce production time by approximately 30%, based on the average time it takes to attach and reattach all of these cables. "Composites in Aerospace." A variation of this trend exists in metallic structures, as more components are conditioned in forgings to get to near-net shape, reducing the amount of machining. High damage tolerance improves accident survivability. Stainless steel resists corrosion and is particularly valuable for use in or near water. IMTS 2014 booth #S-9119. It is 2" wide and handles part widths from 1.375" to 1.800". RedViking is a member of the Control System Integrators Association (CSIA), (www.controlsys.org), a not-for-profit, global trade association for system integration companies. Metallic and composite materials alike continue to be developed and improved to offer ever-increasing performance, whether that’s lighter weight, greater strength, or better heat and corrosion resistance. Formerly only available as special items, Mega Line tools are now available as standard items in a wide range of profiles. It is easy to assemble complex components using automated layup machinery and rotational molding processes. It provides up to 4,000 lb of precision force without distorting workpieces. and 1-30m/min. In doing so, composite materials are helping to drive an industry-wide trend of fewer components in overall assemblies, using one-piece designs wherever possible. Walter USA LLC Battery-free AGVs use inductive power transfer (IPT), a continuous source of power, conveyance, and communication. Together, the materials create a 'hybrid' material that has improved structural properties. The Walter Titex X.treme D40 and the X.treme D50 drills provide 40xD and 50xD drilling depths, respectively. The custom bin-picking solution, designed for components weighing between 1kg and 50kg, delivers the potential for productivity and efficiency increases in a range of parts-producing industries with the cycle times and high availability rates manufacturers require. Aircraft can sustain massive and catastrophic structural damage when making contact with another object at high speeds such as impact with a large bird or hail in a storm cloud.
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