Part 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:

• Mill/Turning
• 5-Axis CNC machining/5-Axis positioning

Cycle Time(s):

• 1^st 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

Part 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:

• 5-Axis Machining (OP1)
• 3-Axis Machining (OP2)
• 5-Axis Positioning
• High-Speed Machining
• Drilling
• Tapping
• On-Machine Deburring
• CNC Machining

Cycle Time(s):

• 1^st 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