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.

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.

 

 


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