Commercial aerospace manufacturers hope to achieve long-term profitable growth. How does CERATIZIT help aerospace manufacturers achieve this goal?

DC: Today's aerospace OEMs and Tier 1, 2 and 3 suppliers can benefit from CERATIZIT's extensive tool portfolio and deep industry knowledge. We provide the best cutting performance, precision and quality. Whether it is used for aircraft and assembly, milling parts of turbine engine components, rotating parts of landing gear, or drilling wing ribs, CERATIZIT provides indexable and solid carbide solutions to help manufacturers achieve strict tolerances , Easily handle difficult materials and improve cycle time to meet growing demand.

DC: For today's advanced materials, such as fiber composites, aluminum, titanium, and high-temperature alloys, we use the 50 years of experience in the KLENK mold production line. Special diamond-coated carbide drill bits, milling cutters, reamers, counterbores and multi-function tools are specially developed for these difficult-to-machine materials. They are used for manual, semi-automatic and automatic drilling, the cost of each quality hole Lower. Specially designed uncoated and diamond-coated solid carbide drills, reamers, CFRP milling cutters, countersinks, and multi-tools for drilling/countsinking can also reduce your cost per hole.

DC: By using our extensive tool portfolio, customers can precisely machine turbine blades, fan boxes and blisks made of titanium, HRSA and Inconel. CERATIZIT's cutting solutions provide the latest PVD ​​coated carbide ISO turning tools, solid carbide end mills and drill bits. KOMET brand solutions, such as reamers, provide precision holes with excellent surface quality in HRSA. These end mills, drills, and reamers are made in the United States, and whether you are grooving the inner diameter of the blisk or drilling precise holes in the titanium combustion box, you can easily handle hard materials.

DC: Machining difficult-to-machine materials will shorten tool life. You can extend tool life by using tools with Dragonskin coating. As it sounds, this advanced coating technology is as tough as a dragon's skin. It provides an additional layer of protection against the high temperatures, up to 1,000°C and extreme wear that occur when processing aerospace components.

For nearly 100 years, CERATIZIT Group has been a pioneer in the development of innovative solutions for mold and hard material technology. For aerospace and other industries, we continue to develop and test products and processes to ensure that your business achieves its strategic goals, thereby ensuring future profitability. In the United States, we are proud to design and manufacture highly specialized precision cutting tools for drilling, boring, reaming, milling and turning in cutting solutions under the CERATIZIT, KOMET, WNT and KLENK brands.

To learn more about CERATIZIT's American aerospace capabilities, please visit: https://cuttingtools.ceratizit.com/us/en.html

Milling strategies, grades and system modularity are essential to increase productivity.

The use of solid carbide end mills is increasing. However, when processing high-temperature alloys and titanium alloys, special attention must be paid to their poor thermal conductivity, strength and hardness at high temperatures.

The use of radial meshing less than 20% of the tool diameter is both light and fast. By using large AP and low AE, as well as a controlled maximum chip thickness, the cutting force can be controlled and smooth cutting is provided. Low AE engagement improves stability and allows higher feed rates, ultimately increasing productivity and tool life. Solid carbide end mills perfectly support this technology.

Sandvik Coromant end mills meet the requirements of material machinability. For nickel alloys, CoroMill® Plura solid carbide end mill grade GC1710 can provide sharp, controllable edge lines and hard, wear-resistant, fine-grained substrates. This material can withstand high working loads when processing hard, high-viscosity, and work-hardened materials (such as aging Inconel 718). Titanium end mills are made of GC1745, developed with new coating technology, with excellent wear resistance and low thermal conductivity. This grade is based on a tough submicron cemented carbide substrate with sharp, controlled edges and is suitable for demanding aerospace milling operations. The inclination of these tools is uneven to avoid chattering, while achieving higher speeds to increase productivity and process safety.

The system provides the required reach through various tool holders and adapters. Combine the Coromant EH system with the universal CoroMill® 316, an interchangeable head milling system tailored to your unique application and material.

The plunge milling strategy is applied to make the manufacture of small and deep grooves and cavities more time-saving and economical. The unique CoroMill® Plura Gannet solid carbide end mills are specially designed for plunge milling and are ideal for tools with limited diameters and long overhangs. CoroMill® Plura Gannet is a safe and efficient solution for rough machining of blisks and impellers, using its materials and geometries optimized for HRSA materials.

For a general solution, try using a hydraulic chuck such as CoroChuck® 930. CoroChuck® 930 has the best pull-out safety on the market, eliminates vibration, and achieves excellent stability and accessibility. These tools can be tightened and loosened quickly and easily without external equipment (such as induction heating devices). These tools also provide tolerances of a few microns to improve surface finish, precision and quality.

The author William Durow is Sandvik Coromant’s Global Engineering Project Office Manager-Aerospace, Aerospace and Defense

Jim Mayer and Pat Cratty of BIG KAISER discuss the advantages of using pre-tuners in the aerospace industry.

The Christmas tree cutter used for blade milling can accurately cut the material and provide the required surface finish. Historically, these forming tools were measured in CNC machine tools with probes, which meant that the spindle was not running. Other traditional measurement methods will reduce the ability to measure runout and will not define any suspicious cutting edges. Using the scan function of the presetter, the operator can measure the unique geometry and determine the length, diameter and runout to program the CNC machine.

Using the presetter/auto shrink combination to set the tool length within 0.0002" tolerance provides many benefits for the aerospace workshop. Anyone engaged in close tolerance 5-axis machining knows that clearance and collision avoidance are essential. Precise control The hot-fitted extension tool significantly reduces the possibility of collision and improves the surface finish.

The data written on the RFID data chip of the preset station can be read by the machine tool, thereby providing fast and accurate data transmission. The RFID solution also ensures that the tool holder is placed in the correct pocket of the tool magazine. The latest development in transferring data from the presetter to the machine tool is SPI, which is Speroni's post-processor interface without intervention. There are many ways to deploy SPI, including using a handheld wireless scanner to link directly from a preset station to the machine tool. The scanner can publish offsets to various machine tools and can be configured to meet workflow requirements.

Most use CAM integration to transfer tool data to the presetter, without setting paper, and to prevent human error and information loss due to misplaced files. CAM software allows programmers to identify the best tool path and efficient cutting tool. The integration of CAM and presetter can help programmers decide which tools to use to manufacture specific parts and which tool components are available by accessing the tools and adapter management functions in the presetter software.

Probes and lasers in CNC machine tools are a good way to spot check tools, but machine tools are not used to measure tools. The offline presetter measures the tools efficiently and accurately and keeps the spindle running. The probe and laser are dedicated to one machine. The offline presetter can set the tools that enter multiple machine tools. It is also difficult for contact probes to measure tools with unique geometries, such as step drills, and cannot identify the first thread on the tap. The offline presetter recognizes tool wear through the camera to ensure accuracy that tool probes and lasers cannot achieve.

More information: https://www.bigkaiser.com

Starrag STC 800X provides Schaller Group with diversified growth opportunities.

Speed, power and precision are qualities that Justin and Maryann Schaller dream of, whether it is the Schaller Group family business or their other shared passion for seaplane racing (see sidebar below). The siblings hold administrative positions in the Schaller Group, a third-generation precision metal forming and assembly company based in Michigan that manufactures parts for the aerospace, military, automotive, and medical industries.

For 10 years, the Schaller brothers and sisters have run their own CNC machining company, but in 2018 they chose to bring their expertise back to the family-owned stamping business. The company expanded one of its factories to 90,000 square feet. It is designated for CNC machining and is one of the six specialized manufacturing plants operated by the Schaller Group in the Detroit area of ​​Michigan.

STC 800X is very suitable for processing complex aluminum materials. Schaller is capable of continuous 5-axis milling using a rotary table and a 120kW tilting spindle (S1), which can process at speeds of up to 162hp and 30,000rpm. In the range of -100°/ 60° A axis, no angle head is needed when processing aerospace structures. The turntable allows economic processing by using tombstone settings or multiple parts and fixtures on the same table. In addition, Schaller's STC has been integrated into the manufacturing system for flexibility.

"This is the perfect machine for our growth plan," says business development expert Maryann Schaller. "We recently laid the foundation for adding a second STC 800X to our operations. Because we purchased the first STC 800X flexible manufacturing system (FMS), we can have multiple machines on one production line."

An example of new opportunities is medical equipment. In March 2020, Schaller Group manufactured and donated parts for a university's prototype ventilator project, hoping to help respond to the COVID-19 crisis. Although the project was not as successful as expected, it showed Schaller another market in which the Starrag STC 800X would be of great benefit.

"The speed and accuracy of these machines are important reasons why we chose Starrag," Maryann said.

Justin Schaller, chief technical expert of the Schaller Group, said that the process of customers from research to demonstration, purchase and installation is seamless. "I don't even think of myself as a Starrag customer. Our relationship is more like a partnership."

The partnership was formed at the International Manufacturing Technology Show (IMTS), and Justin was introduced to Starrag products.

"When the right project appears in 2020, it provides us with the opportunity to purchase the Starrag STC 800X," Justin said.

After the foundation is poured, the installation will be completed in September 2020. However, the project was shelved because additive manufacturing (AM) customers converted their manufacturing into production test swabs for use by healthcare professionals during the pandemic. The customer is now working again with the Schaller Group to complete the original project.

Precision, quality, total cost of ownership and guaranteed 95% uptime are the advantages of Starrag machines. Schaller chose Starrag because the equipment can be used in a wide range of industries—not just aerospace. Other markets that require high-precision, complex parts include various racing cars, satellites, or electric vehicles (EV).

Starrag North American Sales Director Tim Mooney said: "STC 800X is ideal for machining precision parts 55" or smaller, which is exactly what Schaller is expanding into the complex aerospace, defense, and professional industry markets. Having a high degree of machine "reliable and consistent manufacturing of the most challenging parts is part of Starrag's guarantee. This is the real driving force for business development, because manufacturers want their machines to run 24-7 without continuous intervention ."

With the expected growth and diversification, “we will install more Starrag machines,” Maryann said. "For us, Starrag and automation make a lot of sense."

One area of ​​growth pursued by the brothers and sisters of Justin and Maryann Schaller is high-performance racing, and Schallers combines their passion for CNC machining with a love for speed. High-performance motorsports include boats such as jet skis and stylish marine vessels, as well as various forms of racing, such as stock, drag, and rally racing. All of these rely on high-quality aluminum components.

Maryann said: "The Starrag STC 800X is the perfect machine for us to enter the high-performance racing industry. Our seaplane racing experience has exposed us to a network of potential customers. The speed of the machine and the ability to use tombstones on a multi-pallet system will enable us to manufacture Competitive in engine blocks, cylinder heads, manifolds and other high-performance racing products."

Model-based systems engineering (MBSE) provides the tools essential to successfully certify electric aircraft.

The prospects of electric planes and self-driving air taxis are rapidly developing. Aerospace original equipment manufacturers (OEMs) and their supply chain partners are under tremendous pressure to bring safe and reliable products to market first. Due to the complexity and challenges of today, many practices that worked 20 years ago are no longer applicable. Therefore, original equipment manufacturers are rethinking their product development methods, starting with systems engineering. As the company explores the trade-offs between hundreds of design configurations and prepares for the challenge of certifying electric aircraft, systems engineering is critical to its success.

When relying on document-centric systems engineering processes, companies often struggle with the complexity of autonomous systems, flight control, and system integration. The requirements may be in a database, spreadsheet, or document, and the system modeling may be in Microsoft Visio or SysML. System security analysis may be distributed among various tools. Verification and test data usually end up in another spreadsheet. Everything is disconnected and often occurs in isolated work islands. In the rapidly evolving field of future aircraft, with the establishment of new requirements and system architectures, these document-centric methods cannot be extended, and it is almost impossible to manage traceability when trying to solve thousands of system interactions.

A digital approach that links all aspects of concept, design, manufacturing, and maintenance is the answer.

Companies that are leading the way in the development of electric aircraft realize the importance of model-based systems engineering (MBSE), which is becoming more and more popular due to its rigorous systems engineering approach. It brings a new level of integration and efficiency to the complex systems and processes of many multi-domain challenges faced by future aircraft manufacturers. When companies move to MBSE, they can more easily collaborate across domains and the entire supply chain.

The MBSE method is more than just functional or logical modeling. As a digital backbone, it combines engineering, manufacturing, supply chain and project management activities to create a comprehensive digital mainline-a complex of interwoven and interconnected digital chains, creating an ecosystem for excellent project execution.

MBSE can meet the following requirements of electric aircraft manufacturers:

Support the entire life cycle of product development-MBSE allows the team to troubleshoot, explore, and determine the desired results. Thanks to the MBSE digital thread, what happens in a domain is shared throughout the product life cycle. For example, electric motors are different from traditional turbine engines. The center of gravity is in a different position and has a different weight. Before installing an engine on an aircraft, engineers must consider weight and balance trade-offs, and how they will affect downstream activities.

Another challenge is to determine where to place the batteries, as they will significantly increase the weight of an all-electric aircraft. Using MBSE allows the team to purposefully design and build a structure that includes higher electrification. Batteries, and more importantly power density, are a key design challenge for electric aircraft (Figure 1 below). When these challenges are met, product risks will be reduced and certification will become easier.

Certification-As companies seek to certify more complex and highly integrated systems, MBSE is becoming more and more widely used. The Federal Aviation Administration (FAA), European Union Aviation Safety Agency (EASA), and other regulatory agencies require OEMs and their partners to conduct more organized systems engineering. The US Department of Defense (DOD) also recognizes that MBSE needs to communicate requirements to OEMs more effectively and develop a process to check whether all requirements have been met. The powerful MBSE digital thread enables the company to speed up its product development and certification process, while improving communication with various regulatory agencies.

It is not just the propulsion system of the electric aircraft that is different, but the entire vehicle configuration. The FAA has rules for fixed-wing aircraft, rotary-wing aircraft, and tilt-rotor aircraft-all of which add another layer of complexity to certification requirements-which makes MBSE critical in aircraft certification.

Manage product architecture-The product architecture needs to ensure that the OEM manages all product interfaces, including electrical systems, flight control systems, and propulsion systems. All these functions represent interfaces that must be managed. With MBSE, the team has a good process to manage requirements and tie the project model together. This also provides a good verification plan for OEMs. Engineers can verify at the component level, subsystem level, and aircraft level, knowing that all requirements have been met. The MBSE digital thread connects the requirements to the model, design, analysis, and finally to the verification process and artifacts. Using digital threads to automate these data transfers provides complete traceability. Other key areas include thermal management and solving electromagnetic interference problems.

The MBSE digital thread connects multiple domains within the digital enterprise. In addition to the MBSE digital thread, there are also digital threads from every basic field. Through the tight integration of the MBSE digital thread, teams from all areas can test and push boundaries without compromising downstream work or schedules. When companies transition from system modeling to the use of digital threads, they can use any system modeling tool and connect to the entire data and information lifecycle to certify, deliver, and maintain new products. From conceptual design to service, all relevant data needs to be easily accessed through a comprehensive digital thread, and should be built on a flexible and open ecosystem that can accommodate a variety of tools for requirements and system modeling, while ensuring Customers can host their architecture and traditional tools as they develop MBSE functions and move forward.

Many people in the industry believe that requirements engineering or system modeling is MBSE. To some extent this is true, but MBSE is also about system security, software engineering, verification-all of which are closely related to product design, optimization, manufacturing, and product support. Aerospace companies involved in electric aircraft are implementing Siemens MBSE digital threads to accelerate product development and take the lead to market. They move faster than their competitors and are in line with project budget guidelines. They are reducing the risk of design changes. When changes occur, they will better understand how to make such changes and how to deal with the chain reactions that follow. MBSE is the right choice to lead our industry forward.

Siemens Digital Industries Software About the author: Dale Tutt is the vice president of aerospace and defense industry at Siemens Digital Industries Software. You can contact him at dale.tutt@siemens.com.