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.

Hoist Link

Hoist LinkCustomer:  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.

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.

Hoist Fitting

Hoist Fitting

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

 


Bracket

Hinge Bracket

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):

  • 1st 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.

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.

Lift Mechanism Arm

Lift Mechanism ArmPart 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.

 


Door Hinge

Aerospace Door HingePart 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:

Cycle Time(s):

  • 1st 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.