Part Name: Motor Housing
Customer: Aerospace Tier 2
Location: US
Materials: 6061-T6511 Aluminum
Description: Housing for electrical motor controlling environmental systems on aircraft
Industry: Aerospace (Commercial)
Quality Details & Requirements:
- Bearing seats: 2 precision inline bores: +.0004”/-.0” diameter tolerance
- .001” coaxial bores
- ID .001” total tolerance
- .0005” tolerance for alignment pins between housing halves
Quantity: 80 sets with yearly repeat orders
Part Size & Dimensions:
- Diameter = 6”
- Length = 11”
Application(s) Used:
- 5-Axis Positioning CNC Machining
- Mill/Turn
- Sinker EDM of recessed slots in large half
- Precision Boring
- Slotting of fins using customer form saw
- Minor assembly - instillation of heli-coils after plating
- Thread Milling
Cycle Time(s):
Large Half
- Milling and Turning, Protoypes: 5.5 hours
- Milling and Turning, Production: 2.25 hours
- Sinker EDM: 1 hour
Small Half
- Milling and Turning, Protoypes: 3.75 hours
- Milling and Turning, Production: 1.5 hours
Engineering & Software Requirements:
- Customer supplied STEP file
- PDF Drawing
- TopSolid/TopCAM for CNC programming
Special Processes:
- Chormate Conversion (Iridite) Per MIL-C-5541 E Class 1A, light brown
Project Milestones:
- Multi-year project. Work with customer from single piece prototypes to production.
- Worked with customer on several revisions rounds
- Original prototypes used micro tapered end mill which proved to be extremely time consuming and highly unreliable due to tool breakage. Developed process for machining fins using custom designed form slitting saw…dramatically reducing cycle times and improving part quality.
- GTI had to change to a different secondary processor on second production round due to poor vendor performance. Customer was very pleased with second vendor’s performance on finish and color. Precision diameters unaffected by chemical process with new vendor.