Chassis 2

 

Defense/Optics Aluminum ChassisPart Description: Chassis

Customer:  Defense

Location: USA

Part Name: Chassis

Industry: Defense/Optics

Materials: 6061-T651 Aluminum

Quality Details & Requirements:

  • Line boring for shaft.  .0004″ [.010 mm]
  • Bearing seat diameters + .0002″/ -0 [.005 mm]
  • 18 dimensions on part under .0008″
  • Install all M2.5x.45 helicoil hardware insert after secondary processing
  • N6 surface finish and .0005″ [.015 mm] profile tolerance on mounting surfaces
  • .0004″ [.01 mm] parallel tolerance between all mounting surfaces
  • M2 x .4, M2.5 x .45-6H, M3 x .5 GH Threads

Quantity:  400

Part Size & Dimensions:

  • Height = 1.220” [31 mm]
  • Width = 1.909” [48.5 mm]
  • Length =2.390” [60.69 mm]

Application(s) Used:

Engineering & Software Requirements:

  • Solidworks CAD File
  • PDF Drawings
  • TopSolid/TopCAM for CNC Programming and Fixture Design

Secondary Process:

  • Chemical Conversion Coating per MIL-C5541, Class 3
  • Anodic Coating per MIL-A-8625, Type II, Class 2 Black
  • Masking of all precision diameters and mounting surfaces

Project Milestones:

  • Worked with customer to clearly understand Metric tolerancing, all secondary processing and assembly requirements.
  • GTI implemented use of miniature metric cutting tools from Seco tools, Jabro series.  Small diameters with long reach designs for high metal removal.

Chassis

Chassis

Part Name: Chassis

Customer:  Defense

Location: USA

Industry: Defense/Optics

Materials: 6061-T651 Aluminum

Quality Details & Requirements:

  • Line boring for shaft.  .0004″ [.010 mm]
  • Bearing seat diameters + .0002″/ -0 [.005 mm]
  • 18 dimensions on part under .0008″
  • Install all M2.5x.45 helicoil hardware insert after secondary processing
  • N6 surface finish and .0008″ [.02 mm] profile tolerance on mounting surfaces
  • .0004″ [.01 mm] parallel tolerance between all mounting surfaces

Quantity:  400

Part Size & Dimensions:

  • Height = 1.77” [45.2 mm]
  • Width = 2.165” [55 mm]
  • Length =2.952” [75 mm]

Application(s) Used:

Engineering & Software Requirements:

  • Solidworks CAD File
  • PDF Drawings
  • TopSolid/TopCAM for CNC Programing and Fixture Design

Secondary Processes:

  • Chemical Conversion Coating per MIL-C5541, Class 3
  • Anodic Coating per MIL-A-8625, Type II, Class 2 Black
  • Masking of all precision diameters and mounting sufaces

Project Milestones:

  • Developted a process for deep hole drilling and boring to maintain alignment of bearing seats for shaft assembly.   Max tolerance for  concentricity was +/- .0002”.
  • Worked with customer to clearly understand Metric tolerancing, all secondary processing and assembly requirements.
  • GTI implemented use of minature metric cutting tools from Seco tools, Jabro series.  Small diameters with long reach designs for high metal removal.

Cable Head Cover

Cable Head Cover

Part Name: Cable Head Connector Housing

Customer:  Aerospace/Commercial OEM

Location: USA

Part Name: Cable Head Connector Housing

Industry:  Defense

Materials: 6061-T651 Aluminum

Quality Details & Requirements:

  • O-Ring Groove, + .002″/-0 on groove depth
  • Precision Bores for alignment of cover to mating part, +.0004″/ – 0 [H7]
  • N6 Surface finish on sealing surface
  • Flatness tolerance of .004″ [.05mm] across entire sealing surface

Quantity:  400

Part Size & Dimensions:

  • Height = 1.062” [27 mm)
  • Width = 2.854" [72.5 mm]
  • Length = 5.590” [142 mm]

Application(s) Used:

  • 3-Axis CNC Machining, 2 Set ups
  • High-Speed Machining
  • Thread Milling (M2.5 x .45 6H)
  • Reaming
  • Trochoidal Milling

Engineering & Software Requirements:

  • Solidworks CAD File
  • PDF Drawings
  • TopSolid/TopCAM for CNC Programing

Secondary Process:

  • Chemical Conversion Coating per MIL-C5541, Class 3
  • Anodic Coating per MIL-A-8625, Type II, Class 2 Black
  • Masking of all precision diameters

Project Milestones:

  • Developed machining process for dovetail shaped O-Ring goove
  • Worked with customer to clearly understand Metric dimensioning/tolerancing

 


Window Frame

 

Window FramePart Name: Window Frame

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • 2 precision .500” bores per part, diameter +.0005”/-.0005”
  • Coaxial  .002” tolerance

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 11”
  • Width = 3.5”
  • Length = 11”

Application(s) Used:

  • 5-Axis Positioning  CNC Machining on OP1
  • 2-Axis  and 3-Axis CNC Machining on OP2
  • High-Speed Machining
  • 3-Axis contouring of window seal seat and IML Surface

Cycle Time(s):

  •  OP1 = 1.5 hours
  • OP2  = 45 minutes
  • Total = 2.25 hours

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

Project Milestones:

  • Part had a lot of material to remove in deep pockets and profiles.  Tools with 5X length to diameter ratios required in many places. 
  • Dowel pin locations placed in the interior of the part on OP1 were used to locate the part on a grid plate of another machine for OP 2 position.

Longeron

Longeron - Aerospace StructurePart Name: Longeron

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • .005” Profile tolerance on IML Surface
  • .005″ Flatness on back of part in free state

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 2.92”
  • Width = .75”
  • Length = 14”

Application(s) Used:

  • 3-Axis machining of IML Surface
  • High-Speed Machining of pockets

Cycle Time(s):  OP1 = 27:35 minutes

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

 Project Milestones:

  • Positioned stock on two dovetail fixtures.  Used high speed machining (18K RPM) to rapidly remove material.  Small tool diameters reduced tool pressure on thin floor/wall part improving surface finish and reducing hand finishing.

Intercoastals

IntercostalsPart Name: Intercostal

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • .005” Profile tolerance on IML Surface
  • .625” diameter bore, +.0005/-.0005” tolerance, .005” True Positioning  tolerance

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 4.01”
  • Width = .810”
  • Length = 13.58”

Application(s) Used:

  • 5-Axis Simultaneous machining of IML Surface
  • High-Speed Machining
  • Precision Boring

Cycle Time(s):  OP1 = 34 minutes

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

 Project Milestones:

  • Positioned stock on two dovetail fixtures.  Used high speed machining (18K RPM) to rapidly remove material.  Small tool diameters reduced tool pressure on thin floor/wall part improving surface finish and reducing hand finishing.

 


Longeron, AFT

Aft Longeron

Part Name: Longeron, AFT

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • .005” Profile tolerance on IML Surface

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 3.5”
  • Width = .800”
  • Length = 10.5”

Application(s) Used:

  • 5-Axis Simultaneous machining of IML Surface
  • 5-Axis Positioning of pilot holes
  • High-Speed Machining

Cycle Time(s):  OP1 = 25 minutes

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

 Project Milestones:

  • Positioned stock on two dovetail fixtures.  Used high speed machining (18K RPM) to rapidly remove material.  Small tool diameters reduced tool pressure on thin floor/wall part improving surface finish and reducing hand finishing.

Frame

Recon Frame

Part Name: Frame

Customer:  Aerospace Tier 1

Location: US

Description: Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • .010” General profile tolerance on IML surface
  • 3 precision bores per part, diameter +.0005”/-.0005”

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 5.5”
  • Width = 2.4”
  • Length = 16”

Application(s) Used:

  • 5-Axis Positioning, CNC Machining
  • High-Speed Machining
  • 3-Axis contouring of 2 direction curved 3D surfaces

Cycle Time(s):  OP1 = 1.5 hours

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

Project Milestones:

  • Machined part in one operation on dovetail fixtures
  • Maintained set-up of 3 separate boring heads for precision bores under LEAN initiative
  • Implemented tool extension for long reach .098” pilot holes drilled into center web

 


Fitting, Lower Corner

 

Lower Right Corner Fitting - AerostructurePart Name: Fitting, Lower Corner

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • .005” General profile tolerance on IML surface
  • .05” thick webs
  • .01” true positioning of holes

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 12”
  • Width = 1.5”
  • Length = 12”

Application(s) Used:

  • 5-Axis Simultaneous machining of OML Surfaces
  • High-Speed Machining
  • 3-Axis contouring of 2 direction curved 3D surfaces

Cycle Time(s):  OP1 = 46 minutes

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

 Project Milestones:

  • Part machined using picture frame method on dovetail fixtures in one operation.  Extensive 3-Axis contouring at 18,000+ rpm was required to produce thin walls with a high quality finish, reducing deburring and hand finishing of all surfaces.

Upper Corner Fitting

Upper Corner Fitting

Part Name: Fitting Upper Corner

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

  • 3 precision bores: +.0004”/-.0” diameter tolerance
  • .001” coaxial bores

Quantity:  55 Total ship sets, 1 part per ship set

Part Size & Dimensions:

  • Height = 6”
  • Width = 2.5”
  • Length = 10.5”

Application(s) Used:

  • 5-Axis Simultaneous machining of OML Surface and pockets
  • High-Speed Machining
  • Precision Boring

Cycle Time(s): OP1 = 48 minutes

Engineering & Software Requirements:

  • NX CAD File
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Ultrasonic Inspection, MIL-STD-2154, CL A
  • Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
  • Non-Chromic Anodize, MIL-A-8625, TYP-1C
  • Epoxy primer, BMS10-11, TYP 1

Project Milestones:

  • 3 precision bores per part required the purchase of special tooling to properly machine each size.  Following a LEAN strategy the boring tools we set up and maintained for these parts exclusively thus reducing machining variants and eliminating scrap each time the part was run.

Optical Mirror Mount

 

Optical Mirror MountPart Name/Description: Mirror Mount for Sighting Laser

Customer: Optics OEM

Location: Western US
Materials: 6061-T651 Aluminum

Industry:  Optics (Commercial)

Quality Details & Requirements:

  • Flatness of mirror bonding surface .0005”
  • .001” true positioning between axis of rotation
  • 32 RMS finish on bonding surface
  • Roundness of bosses to .0002”
  • Irradite secondary process

Quantity:  100

Part Size & Dimensions:

  • Height = .250”
  • Width = 2”
  • Length = 2.5”

Application(s) Used:

Cycle Time(s):

  • 1st Part in Run = 50 minutes
  • Last Part in Run = 38 minutes

Engineering & Software Requirements:

  • Solidworks Model
  • PDF Drawings
  • TopSolid/TopCAM

Project Milestones:

  • Developed a process for machining part in one set up by standing part up so that we could machine both sides of the part in one fixturing
  • Eliminated the requirement for stress relieving through the use of high speed machining
  • Utilized trepan style cutting tool for machining rotation bosses

Electronics Enclosure

Electronics EnclosurePart Name/Description: Ultra-Rugged Electronics Enclosure

Customer: International Aerospace/Military Manufacturer

Location: Israel

Materials: 6061–T651 Aluminum

Industry: Aerospace (Military)

Quality Details & Requirements:

  • Special Customer-Mandated Project & Technical Specifications
  • No Foreign-Supplied Raw Materials
  • Silver Plating
  • ITAR Compliance

Quantity: 1,000 Total (1-Year Duration)

Part Size & Dimensions:

  • Height = 1/2” [12.7 mm]
  • Width = 3 1/2” [88 mm]
  • Length = 7 7/8” [200 mm]

Application(s) Used:

Cycle Time(s):

  • 1st Part in Run = 45 minutes cycle time
  • Optimized cutting & toolpath strategies; Rewrote Computer Aided Manufacturing (CAM) programming to improve Roughing & Finishing details
  • Last Part in Run = 29 minutes cycle time

Engineering & Software Requirements:

  • Solidworks Computer Aided Design (CAD) File
  • PDF Drawings
  • TopSolid/TopCAM Modeler
  • CAM Program Refinements Throughout Project

Project Milestones:

  • High Raw Materials Inventory Maintained Throughout Year-Long Project
  • On-Machine Deburring Programming Developed to Reduce Cycle Time