Part 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:

• 5-Axis CNC Machining (Op 1)
• 3-Axis CNC Machining (Op 2)
• High-Speed Machining
• Thread Milling
• Micro Slitting Saw

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.

Part Name:

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.

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:

• 5-Axis CNC Machining (Op 1)
• 3-Axis CNC Machining (Op 2)
• High-Speed Machining
• Thread Milling

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.

Part Name: Cable Head Connector Housing

Customer:  Aerospace/Commercial OEM

Location: USA

Part Name: Cable Head Connector Housing

Industry:  Defense

Materials: 6061-T651 Aluminum

Quality Details & Requirements:

• O-Ring Groove, + .002″/-0 on groove depth
• Precision Bores for alignment of cover to mating part, +.0004″/ – 0 [H7]
• N6 Surface finish on sealing surface
• Flatness tolerance of .004″ [.05mm] across entire sealing surface

Quantity:  400

Part Size & Dimensions:

• Height = 1.062” [27 mm)
• Width = 2.854" [72.5 mm]
• Length = 5.590” [142 mm]

Application(s) Used:

• 3-Axis CNC Machining, 2 Set ups
• High-Speed Machining
• Thread Milling (M2.5 x .45 6H)
• Reaming
• Trochoidal Milling

Engineering & Software Requirements:

• Solidworks CAD File
• PDF Drawings
• TopSolid/TopCAM for CNC Programing

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

Project Milestones:

• Developed machining process for dovetail shaped O-Ring goove
• Worked with customer to clearly understand Metric dimensioning/tolerancing

Part Name:

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.

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:

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.

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:

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.