In the production business, the name of the game is to be able to produce a quality product in a timely manner while having profitable margins. In aircraft part manufacturing there are multiple ways to optimize the production process to achieve these goals while still maintaining the high standard that one must achieve for aerospace fabrication. We sat down with Platform Aerospace's Lead Machinist, James "Jimbo" Epp to offer up some key considerations if you want to optimize aircraft part production.
1. Up To Date Technology
Staying up to date with technology is a key factor in a production facility. Every year new products come out that can help speed up a process. This could be a piece of quality control equipment, ERP software, new CNC machines, or even having multiple types of machinery. We just added the Haas UMC-1000SS, their latest and greatest 5 axis machine. This not only allows us to produce larger parts much faster, but also frees up our other machines to work on other projects.
2. Optimize Tooling Setup
Another major time saver is to have common preloaded tools setup across all of your CNC machines. In our shop, we have 3 VMC’s (Vertical Machining Centers). Between all three, we have common tools set. An example would be 2” Facemill is in Tool 1, ½” Flat End Mill in Tool 2 etc. This allows us to share programs between machines and have common tools set between them all. If this isn’t kept consistent this can create an unorganized environment resulting in lost time from having to move tools around and potentially avoids mistakes due to the wrong tools being loaded in the machine.
3. Simulations
Just like the expression “there are multiple ways to skin a cat”, there are multiple ways to program toolpaths on a part. Simulations allow you to test your part in a machining environment to do time studies and verify toolpaths to prevent mishaps. We run multiple simulations before we load a program into the machine and often enough, we can catch an error before it even happens. Also, this has allowed us to discover a more efficient way of machining a part as well.
4. Trichordial Machining
This is the most optimal programming method because it allows the machinist to push the tooling to its maximum potential with much less chance of tool breakage. Trichoridial machining allows an end mill to keep at the consistent tool engagement the entire path. This keeps the tool at a constant chip load which extends the life of the tool while also allowing the user to increase cutting speeds. This is greatly noticed in the length of tool life as well as surface finish on a part which in the aerospace industry can be extremely critical.
5. Training with Tooling / Programming / Setup Efficiency
Arguably one of the most import aspects of a machine shop is the human side of machining. Unlike the popcorn button on the microwave, you can’t push a button and out pops a perfectly machined part from a billet block. This is where the mind of a machinist comes into play. This can make the difference between a 6/day 3 setup part down to a 2/day 1 setup part. This really comes down to training. A good machinist should know what the tools are designed to handle as well as how to program those tools correctly to ensure maximum tool life. When a machinist fully understands this, they will know how to incorporate all the steps mentioned above to produce a quality product in a timely manner that saves the client time and money.
Having said that, the only difference between these two parts pictured here, is the one on the left took 4 setups and 1 day of machining vs the one on the right took 1 setup and 30 min of machining.
Here at Platform Aerospace, our shop houses some of the most cutting edge fabrication equipment including, (3) 3/5-Axis CNC machining centers with capacities as large as 84” x 40”, Live Tool CNC Lathe, Tilting Axis CNC Waterjet, Precision Cut Saws, Large Cross Draft Paint Booth, electrical cable harness building equipment, carbon fiber part kits, and an extensive assortment of precision tools to get the job done right. Learn more at https://platformaerospace.com/parts-manufacturing.
