Part 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.

Part 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.

Part 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.

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.

Customer:  Aerospace/Commercial OEM

Part Name: Hoist Link

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure, Door component

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

• Four precision same size bores:  .0007” total tolerance
• Coaxial bores,  .002” tolerance

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

Part Size & Dimensions:

• Height = 5.55”
• Width = 5.28”
• Length = 8.5”

Application(s) Used:

• 5-Axis Positioning, CNC Machining OP1
• High-Speed Machining
• Precision Boring

Cycle Time(s):  OP1 = 22 minutes

Engineering & Software Requirements:

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

Special Processes:

• Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
• Non-Chromic Anodize, MIL-A-8625, TYP-1C
• Epoxy primer, BMS10-11, TYP 1
• Semi Gloss Enamel White Top coat, BMS10-11, TYP 2, BAC 702

Project Milestones:

• 1 precision bore, 4X per part required a dedicated boring head for this P/N.  Following a LEAN strategy the boring tools we set up and maintained for this part exclusively thus reducing machining variants and eliminating scrap each time the part was run.

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

Part 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.

Part Name: Hoist Fitting

 Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

• .01” profile tolerance
• .005” profile tolerance on OML & IML contours

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

Part Size & Dimensions:

• Height = 2.52”
• Width = 2.0”
• Length = 2.55”

Application(s) Used:

• 5-Axis Positioning  CNC Machining
• 3-axis contouring of two direction curved OML & IML contours
• Thread milling

Cycle Time(s):

•  OP1 = 20 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:

• Thread milled .875-14F-3B Thread
• Applied proven machining process to a family of 6 part numbers

Part Name: Bracket

Customer:  Aerospace Tier 1

Location: US

Description:  Aerostructure

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

• 1 precision bores: +.0005”/-.0” diameter tolerance
• .001” coaxial bores

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

Part Size & Dimensions:

• Height = 1.81”
• Width = 1.0”
• Length = 3.66”

Application(s) Used:

• 5-Axis Positioning , CNC Machining
• Precision Boring

Cycle Time(s):  OP1 = 15 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

 Aerospace/Commercial OEM

Location: US

Part Name/Description: Door hinge used in Aft section of a Single Isle Commercial aircraft,90- 110 seats

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

• Line boring of bearing seats, +0/ -.0005” tolerance
• .010” profile tolerance on all

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

Part Size & Dimensions:

• Height = 3”
• Width = 6”
• Length = 10”

Application(s) Used:

• 5-Axis CNC Machining (machined in 1 operation)
• High-Speed Machining
• Drilling
• Trochoidal Milling

Cycle Time(s):

• 1^st Part in Run = 2 hours
• Last Part in Run = 1 hour 15 minutes

Engineering & Software Requirements:

• NX CAD File
• PDF Drawings
• TopSolid/TopCAM

Project Milestones:

• Developted a process for deep hole drilling and boring to maintain alignment of bushing seats.   Max tolerance for  concentricity was +/- .0002”.  This was obtained by using three stage machining process that allow consistant repeatability over the entire run of 55 pieces.
• Applied drilling process to 8 other hinges in a family of parts.

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.

Part Name: Lift Arm Mechanism

Customer:  Aerospace Tier 1

Location: US

Description: Cargo Door component Commercial aircraft, 75-95 seat

Industry: Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

• Various diameter precision bores: +.0005”/-.0005” tolerance
• .002” coaxial bores

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

Part Size & Dimensions:

• Height = 1.81”
• Width = 5.28”
• Length = 15.73”

Application(s) Used:

• 5-Axis Positioning, CNC Machining OP1
• 2-Axis CNC machining OP2
• High-Speed Machining
• Precision Boring
• Deep slot milling

Cycle Time(s):

•  OP1 = 48 minutes
•  OP1 = 15 minutes

Engineering & Software Requirements:

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

Special Processes:

• Liquid Penetrant Inspect, ASTM-E-1417, TYP-1
• Non-Chromic Anodize, MIL-A-8625, TYP-1C
• Epoxy primer, BMS10-11, TYP 1
• Semi Gloss Enamel White Top coat, BMS10-11, TYP 2, BAC 702

Project Milestones:

• 6 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.

Part Name/Description: Door Hinge

Customer: Aerospace/Commercial OEM

Location: US

Part Name/Description: Door hinge used in Aft section of a Single Isle Commercial aircraft,90- 110 seats

Industry:  Aerospace (Commercial)

Materials: 7050-T7451 Aluminum

Quality Details & Requirements:

• Line boring of bearing seats, +0/ -.0005” tolerance
• .010” profile tolerance on all

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

Part Size & Dimensions:

• Height = 3”
• Width = 6”
• Length = 10”

Application(s) Used:

• 5-Axis CNC Machining (machined in 1 operation)
• High-Speed Machining
• Drilling
• Trochoidal Milling

Cycle Time(s):

• 1^st Part in Run = 2 hours
• Last Part in Run = 1 hour 15 minutes

Engineering & Software Requirements:

• NX CAD File
• PDF Drawings
• TopSolid/TopCAM

Project Milestones:

• Developted a process for deep hole drilling and boring to maintain alignment of bushing seats.   Max tolerance for  concentricity was +/- .0002”.  This was obtained by using three stage machining process that allow consistant repeatability over the entire run of 55 pieces.
• Applied drilling process to 8 other hinges in a family of parts.