Adapter Fitting

Stainless Steel Aerospace FittingPart Name: Adapter Fitting

Customer:  Tier 1 Aerospace

Location: USA

Description:  Fluid application

Industry: Aerospace (Commercial)

Materials: 304L Cres Condition A, AMS 5513 Stainless Steel

Quality Details & Requirements:

  • General tolerance +/- .005”
  • Mil Spec thread form

Quantity:  10

Part Size & Dimensions:

  • Height = 2.25”
  • Width = 3”
  • Length= 3”

Application(s) Used:

  • CNC Mill/Turn
  • Deep profiling with small boring bar
  • OD Threading

Engineering & Software Requirements:

  • Pro E CAD file
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes & Requirements:

  • Passivate IAW AMS-QQ-P-35 Type V11

Project Milestones:

  • Customer need to meet a tight deadline on quick turn parts.  After parts were machined GTI Precision Components personnel drove parts to secondary processing vendor for same day turn around service.  After secondary process was completed, parts were inspected, packed and shipped overnight to customer’s facility on time.

Lens Plate

Part Name: Lens Plate

Customer: Test equipment manufacturer

Location: US

Description: Optical assembly component

Industry: Biomed

Materials: 6061-T6511 Aluminum

Quality Details & Requirements:

  • Small Threaded holes, 2-56, 4-40
  •  Precision slot depths and locations for lens seats.  +/- .001”
  • Flatness tolerance .002” in free state
  • Complex and detailed Milled and turned geometry

Quantity:  20

Part Size & Dimensions:

  • Width = .940”
  • Diameter = 5”

Application(s) Used:

  • 5-Axis Positioning  CNC Machining
  • Mill/Turn
  • Slotting using key cutter
  • Thread Milling

Cycle Time(s): 105 minutes

Engineering & Software Requirements:

  • Solidworks file
  • PDF Drawing
  • TopSolid/TopCAM for CNC programming

Special Processes:

  • Clear Anodize, MIL-A-8625F, Type II Class 1

Project Milestones:

  • Developed process and all fixturing for machining on twin spindle mill/turn center.
  • Part machined complete on main and sub-spindle with no involvement by operator for part transfer.

 

 


Motor Housing

Motor Housing

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.

 


Lens Port Housing

Lens Port HousingPart Name/Description: Lens Port Housing

Customer: Optics OEM

Location: US

Materials: 6061-T6511 Aluminum

Industry:  Military Optics

Quality Details & Requirements:

  • 16 RMS Surface finish on ID and OD

Quantity:  200

Part Size & Dimensions:

  • Diameter  = 6.5”
  • Length = 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:

  • Utilized main spindle and sub-spindle for turning and 5-axis positional milling
  • Utilized expanding arbor on sub-spindle ID during part transfer
  • Utilized High Positive insert to create 16 RMS surface finish