1 October 2013 www.aeromag.com www.aero-mag.com THE EUROPEAN MAGAZINE FOR A GLOBAL INDUSTRY CIVIL & DEFENCE/SPACE/SUPPLY CHAIN APRIL 2024 PROGRAMMES: SPACE SECTOR BEYOND INGENUITYPage 14 SHOW PREVIEW PAGE 9
Get the show on the road Editor | Mike Richardson | newsdesk@aero-mag.com | Tel: +44 (0) 1634 825709 Deputy Editor | Ed Hill | ehill@mitpublishing.co.uk | Tel: +44 (0) 1634 825705 Digital content coordinator | Michael Tyrrell | mtyrrell@mitpublishing.co.uk Tel: +44 (0) 1634 825713 Sales Manager | David McCauley dmc@aero-mag.com | Tel: +44 (0)7557 308369 Sales Director | Andy Morley amorley@aero-mag.com | Tel: +44 (0) 1634 825701 Art Editor | Sarah Blake sarahblake@sablemedia.co.uk | Tel: +44 (0) 1233 770781 Production Coordinator| Ewa Hodden ehodden@mitpublishing.co.uk | Tel: +44 (0) 1634 825703 Circulation, Subscriptions and Database Research | Perception SAS aero@mitpublishing.com | Tel: +44 (0) 1825 701520 Financial Controller | Valerie Prentice | accounts@mitpublishing.co.uk Publisher | Liam McCauley Director | David Rose Published by | MIT Publishing Limited | Featherstone House | 375 High Street | Rochester | Kent ME1 1DA | United Kingdom | Tel: +44 (0) 1634 830566 Published 8 times a year, Aerospace Manufacturing is distributed free of charge to applicants in the UK and certain other countries who meet the publishers criteria. Subscriptions are also available at £150 per annum which represents a 40% saving on the single issue price. While every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they may arise. Authors opinions do not necessarily reflect those of the publisher. All rights reserved. No part of this publication may be reproduced or transmitted without the consent of the publisher. Copyright: MIT Publishing Ltd 2024 Printed by: Pureprint Group 5 NEWS EVENTS 9 Ready for take-off at MACH! – MACH 2024 preview AIRCRAFT PROGRAMMES 14 Beyond ingenuity – Space 16 Taking out the interstellar trash – Space TECHNOLOGY FEATURE 18 A deep hole drill thrill! – Landing gear MACHINING TECHNIQUES 20 Reimagine and reshape – Machine tools 22 Look sharp! – Machine tools ADVANCED MATERIALS 24 Tanks on track with STAXX! – Composites SPECIAL REPORT 25 Assuring software quality – Quality & inspection 28 X-ray vision – Quality & inspection 30 All the makings of a flying finish! – Surface treatment DIGITAL MANUFACTURING 32 Getting the signal with digital twin – The digital twin FINAL APPROACH 34 It’s what makes the world go round – Harry Malins, chief innovation officer of the ATI Next issue: Events: Farnborough Airshow preview, Military aircraft, Technology feature: Wings, Materials: Coatings, Machining techniques: Additive manufacturing, Digital manufacturing: CAD/CAM, Final approach Hello and welcome to the April issue of Aerospace Manufacturing magazine. There’s no business like show business, and as the trade exhibition calendar hots up - reaching fever pitch at July’s Farnborough International Airshow - it’s time to take stock of the value in attending these events. In these uncertain economic times, are there justi able reasons for a ‘no show’ by companies that should be seen at these events? The cost of exhibiting can be prohibitive to say the least, while many of us may baulk at the prospect of not only paying ever-increasing travelling and accommodation costs, but also spending valuable time away from our o ces. All things considered, these events serve to add value and tangible bene ts for exhibitors and visitors alike. They highlight industry trends and developments that could otherwise remain undiscovered until a later date, or be overlooked altogether by those most likely to bene t from them. Are they still ‘must attend’ shows? Getting hands-on contact with the latest innovations and the specialists behind them, the opportunity to network and form partnerships – even friendships – with the fellow aerospace professionals we rub shoulders with whilst treading the aisles would suggest they are. Aerospace Manufacturing covers a number of industry events with which we are partnered. This issue contains mentions of the UK’s MACH 2024 and Germany’s Aircra Interiors Expo – exhibitions that serve to showcase the rich diversity of technological achievement the industry continues to unveil before our very eyes. The reason for focusing on such events is that they, along with this publication, are crucial in disseminating knowledge around the industry. A er all, that’s show business. Next up is our May/June Farnborough Airshow preview taster. Until then, stay safe and keep the manufacturing ag ying! Mike Richardson, editor ISSN 2056 3434 www.aero-mag.com Aerospace Manufacturing April 2024 3 COMMENT & CONTENTS Volume 19 Issue 174
www.aero-mag.com Aerospace Manufacturing April 2024 5 NEWS Space-Comm Expo 2024 has con rmed a record number of visitors with over 100 speakers, 170 exhibitors and 4,500 attendees including global leaders from across government, business, aerospace and defence. Held at Farnborough March 6 7, SpaceComm Expo organised by Hub Exhibitions is at the heart of UK ambitions and a new global space economy driven by government collaboration with business and rapid advances in science and technology, opening up new opportunities for the commercialisation of space. Exhibitors included Airbus, Astroscale, BAE, Endurosat, Jacobs, In-Space Missions, Moog, RollsRoyce, Siemens, Space Florida, Viasat and suppliers from the UK and the global space ecosystem. Dr Paul Bate, chief executive of the UK Space Agency, said: “This year’s SpaceComm Expo has been a fantastic event, with so much excitement and energy across the two days. We have seen and heard from much of the UK space sector and beyond, with everyone here united in championing the benets of space for our prosperity and protection on Earth.” The success of Space-Comm Expo over the past ve years has led event organisers Hub Exhibitions to announce plans to move the event from Farnborough to London ExCeL in 2025 for a more central location. Headlining Space-Comm Expo 2025 at London ExCeL 1112 March will be Professor of Particle Physics, media presenter and musician Brian Cox and space business pioneer Will Whitehorn. Space-Comm Expo Scotland will take place at the SEC Glasgow 11 12 Sep 2024 and SpaceComm Expo Dubai at the famous World Trade Centre 27 29 May 2025. Space-Comm Expo attendees this year included the UK Minister of State for Science, Research and Innovation Andrew Grith MP and astronaut Axiom 3 Commander Michael Lopez-Algeria, with leaders from UK Space Agency, Departments of Trade and Transport, Ministry of Defence, UK Space Command, and visiting leaders from NASA, ESA, NATO and international delegations. Kata Escott, managing director of Airbus Defence and Space UK, said: “Space-Comm Expo is a brilliant opportunity to connect with our partners in industry, academia and government, to deepen our collaboration and grow our sector in the UK. It’s a great to speak there about the work Airbus is leading to connect, grow and inspire our ecosystem.” https://space-comm.co.uk Space-Comm confirms record attendance Safran Nacelles has completed the acquisition of 3D Metal Forming (3DMF), a company specialised in high energy hydro forming (HEHF) of metal parts. This innovative manufacturing process reinforces Safran Nacelles’ capacity to develop and produce parts for nacelles and engines, including nozzles and air inlet lips. HEHF is also an enabling technology for manufacturing monolithic integrated structures from thick plate. Located in the Netherlands, 3DMF manufactures prototype and series parts mainly for the aerospace industry. The manufacturing process developed by the company enables the production of a very high quality nished product which can be large and of various thicknesses. It o¢ers dimension and precision characteristics that are above current standards, Safran says. Vincent Caro, CEO of Safran Nacelles, commented: “We are delighted to integrate the 3DMF team in Safran Nacelles. Acquiring this new expertise enables us to enhance our technology portfolio and consolidate our position as a reference aerospace player in the development and manufacture of nacelles. This acquisition will notably enable the design and production of high-tech performanceenhancing parts for our customers, improving the performance of future generation propulsion systems.” www.safran-group.com Safran acquires hydro forming specialist
6 October 2013 www.aeromag.com April 2024 Aerospace Manufacturing www.aero-mag.com NEWS Leading aerospace specialist, Airframe Designs is investing in the very latest technology as it expands its services in 3D printing. The company is meeting the challenge of the aviation industry with its commitment to innovation and technology to reduce waste, make lighter parts for aircra and contribute to its customers’ e orts towards Net Zero. To date, the organisation has invested in a second Stratasys Fortus 450 3D printing machine, a new 5-axis milling machine and new sophisticated resin printing technology to o er increased capability and quality of parts and tools for its increasing customer base. Garry Sellick, additive manufacturing manager at Airframe Designs, said: “Ultimately, we are helping our customers across the aerospace and defence supply chains to achieve many of their goals. This technology enables us to produce lightweight, highly accurate and robust airframe parts and tooling which are delivered at pace, whilst also helping to reduce carbon emissions. This technology gives us increased capability and capacity to produce multi-component parts quicker and more eciently than ever before.” https://airframedesigns.com Airbus has revealed its fully electric CityAirbus NextGen prototype ahead of its maiden ight later this year. The two-tonne class CityAirbus, with a wing span of approximately 12m, is being developed to y with 80km range and to reach a cruise speed of 120km/h, making it suited for operations in major cities for a variety of missions. The unveiling coincided with the opening of the new CityAirbus test centre in Donauwörth, which will be dedicated to testing systems for eVTOL. The centre, which is part of Airbus’ ongoing and long-term investment in Advanced Air Mobility (AAM), began its operations with the CityAirbus NextGen’s power-on in December 2023 and it will be now used for the remaining tests required before the prototype’s maiden ight later in the year. These tests cover the electric motors with their eight rotors as well as the aircra ’s other systems such as ight controls and avionics. Balkiz Sarihan, CEO and head of urban air mobility at Airbus, commented: “Rolling out CityAirbus NextGen for the very ¡rst time is an important and very real step that we are taking towards advanced air mobility and our future product and market. Thank you to our community, team and partners all over the world for helping us make this a reality.” www.airbus.com Airbus reveals electric aircraft prototype Airframe Designs boosts 3D printing services CloudNC’s CAM Assist gets AI boost CloudNC, a manufacturing technology company backed by Autodesk and Lockheed Martin has revealed that its CAM Assist solution can now create programming strategies and toolpaths with AI for 3+2 axis CNC machines. Previously, CAM Assist - which is available as a plug-in for Autodesk’s Fusion so ware - generated machining strategies with AI for manufacturers using 3-axis CNC machines, helping them to create programs for the machines far more quickly than previously possible. The new upgrade means CAM Assist can now provide strategies and toolpaths for 3+2 axis components as well, enabling many more manufacturers to bene¡t from CAM Assist’s eciency gains. With 3+2 axis support in place, CloudNC estimates that CAM Assist now can help around two-thirds of the CNC machining market. “This upgrade is not only a huge step forward in making CAM Assist even more useful for manufacturers around the world, but it is also an incredible technical achievement,” stated CloudNC’s CEO, Dr Andy Cheadle. “From an R&D perspective, 3+2 axis support is exceptionally challenging, as the extra elements it involves introduce more potential ways of making every feature of every component, by several orders of magnitude.” www.cloudnc.com
thyssenkrupp Aerospace and the Mecachrome Group, one of the five largest manufacturers of aerospace parts in Europe, have signed a Memorandum of Understanding (MoU) for a five-year extension of their existing long-term partnership. thyssenkrupp Aerospace will deliver material management solutions to the Mecachrome Group, including the supply of cut-to-size aluminium plates to France and North Africa. The contract covers a range of services, including optimising the use of raw materials, logistics planning to anticipate distribution and delivery challenges. It also incorporates purchasing management, specifically managing Conbid, the consolidated material supply process used for Airbus. New additions to the partnership agreement take advantage of the ‘Materials as a Service’ offering from thyssenkrupp Aerospace, especially the use of a digital control tower for highly effective performance and forecast management. Emmanuel Soubigou, CEO of thyssenkrupp Aerospace France, said: “We’re delighted to sign this MoU and to continue our long-term partnership with Mecachrome. The control tower services that are included in this renewed contract will enable us to provide even better control of the inventory we deliver to Mecachrome so there’s less stockpiling and an efficiency boost to their operations.” www.thyssenkrupp-aerospace.com Thyssenkrupp extends its Mecachrome supply MoU
NEWS ai168976313866_Minigears 109 x 210 Aerospace Advert DEFENCE 2023.pdf 1 19/07/2023 11:39:02 Visit Us On Stand 6C127 28th – 30th May 2024 Hamburg Messe, Germany www.aircraftinteriorsexpo.com Aircra Interiors Expo (AIX) will return to the Hamburg Messe from 28 30 May 2024, showcasing cutting-edge advances in aircra cabin systems, in- ight entertainment and connectivity (IFEC), sustainable cabins and more. This year’s edition will shine a light on the latest trends and serve as the global platform dedicated to transforming the passenger experience and creating the cabin of the future. Last year’s event attracted a myriad of airlines, designers, engineers, speci ers, and manufacturers, with visitor attendance increasing by almost two thirds (59%) on the previous year. Plans are well underway, with AIX set to provide the industry with a chance to identify pioneering solutions, network with industry colleagues, and understand how accessibility and sustainability will impact aircra interiors in the short and long term. As airlines, OEMs, suppliers, and designers gear-up for modernisation strategies, AIX will provide a platform to discover the technologies, services, and hardware that can enhance every aspect of the cabin. From seating, galley equipment, lighting, and LEDs, to cabin management systems, IFEC hardware, and communications, the event will enable attendees to collaborate and nd practical and innovative solutions from more than 400 suppliers. Returning to the show oor will be all the major industry players, including Boeing, Airbus, Recaro, Safran, Panasonic Avionics, and Collins Aerospace - rearming the event’s position as the world’s leading marketplace for airlines and the supply chain to meet. Complementing the major OEMs and suppliers, the show will also welcome companies exhibiting at the show for the rst time: Comi Aerospace, LXM Aero, Peter-Lacke, and Skytec Aerospace will be among those presenting their solutions and services at AIX. Polly Magraw (above), event director of Aircra Interiors Expo, said: “The industry’s unwavering support has continued to propel AIX forward. This year’s show will take cabin concepts to new heights, showcasing a compelling line-up of speakers and sessions that provide solutions for every aspect of the cabin interiors sector. We look forward to bringing together experts and visionaries from airlines, OEMs, suppliers, and designers to discuss the future of the passenger experience.” Passenger Experience Conference (PEC), Aircra Interiors Expo (AIX) and World Travel Catering & Onboard Services Expo (WTCE) return to Hamburg Messe from 2830 May 2024. Together, all three events provide airlines, lessors, and business jet operators with a unique opportunity to transform onboard environments, address consumer expectations, and deliver exceptional travel experiences. www.aircra interiorsexpo.com AIX 2024 to create cabin of the future
www.aero-mag.com Aerospace Manufacturing April 2024 9 EVENTS: MACH 2024 EXHIBITOR ROUNDUP e begin our round-up of exhibitors with Heller (hall 19, stand 330) whose UK factory in Redditch produces selected 4-axis and 5-axis horizontal machining centres (HMCs) for world markets. A particular focus at the show will be Heller’s ability to supply turnkey cells for highly e cient machining of tough titanium and nickel superalloys. Consequently, the machine manufacturer will stress the considerable range of di erent spindles that it manufactures in-house to suit a vast range of applications. For example, the HMC on the stand will be an HF 3500 secondgeneration 5-axis model for which it is possible to select a DC (dynamic cutting) universal direct-drive motor spindle, rated at either HSKA63/16,000rpm/56kW/180Nm or HSKA100/12,000rpm/45kW/400Nm. There is also a PC (power cutting) spindle rated at HSKA100/10,000rpm/45kW/360Nm and an HSKA100/13,000rpm/45kW/228Nm SC (speed cutting) spindle. Two further options with an HSKA63 interface are rated at 12,000rpm/45kW/228Nm (PC) and 18,000rpm/45kW/103Nm (SC). All are produced at Heller’s headquarters in Nürtingen and feature the company’s Zero-Spindle system for rapid interchangeability. The 5-axis machine itself, which is built in Redditch, has a 710 x 750 x 710mm working volume. Next up is Horn Cutting Tools (hall 6, stand 210). The wholly-owned UK subsidiary will exhibit a broad crosssection of its extensive tooling range. These include boring tools, end mills Organised by the UK’s The Manufacturing Technologies Association, MACH 2024, held at the NEC in Birmingham from the 1519 April attracts over 26,000 visitors and more than 600 exhibitors involved in all aspects of metalworking technology. The show will be of signicant interest to stakeholders in the aerospace manufacturing community. W READY FOR TAKE OFF AT MACH! The Heller HF 3500 has many spindle options for different applications (below) Horn’s Supermini system requires only one toolholder for well over 1,000 insert variants (below right)
10 October 2013 www.aeromag.com EVENTS: MACH 2024 EXHIBITOR ROUNDUP April 2024 Aerospace Manufacturing www.aero-mag.com for stainless steel machining, threading tools and many more. One range of tools on display will be the Horn Supermini boring, grooving and chamfering system, a variant with a precision-ground rake face designed for producing ultra- ne bores. The ground cutting edge is free from notches when viewed at a magni cation of x200 and the tool can be used to machine components having an inside diameter from just 0.3mm. A sharp insert geometry ensures process reliability, even with very small infeed and cutting feedrates. The specially developed coating is suitable for stainless steels, non-ferrous metals and others. The Supermini Type 105 system insert requires only one toolholder for well over 1,000 insert variants, which applies equally to le-hand and righthand versions. The patented, dropletshape cross section has a vibrationdamping eect and delivers excellent repeatability during insert exchange and internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal. Horn also oers the tools with face clamping elements that allow the insert to be changed without having to remove the holder from the machine. Moving on, Fintek (hall 19, stand 16) will showcase its developments in post-processing and surface nishing. Fintek is the UK agent for OTEC Präzisions nish disc, drag and stream nishing machines and this year, OTEC has expanded its electro- nishing range. Manufacturers need speed, capacity and precision to meet in-line production needs. With repeatable surface roughness values down to Ra 0.01µm possible, OTEC stream nishing machines meet these objectives. Automation options include increased chain-feed loading and unloading along with full robotised operation. OTEC SF machines can also be equipped with ‘Puls nish’, a technology which produces rapid relative motion between the media and metal workpiece by quickly alternating the direction of the rotating heads. This produces a perfect nish, faster and without compromising workpiece geometry. Alongside OTEC machines, Fintek will bring the RENA Technologies Hirtisation process. This allows it to oer additive part post-processing as a subcontract service. Hirtisation removes support structures, powder cakes and partially melted grains and penetrates complex geometries and small diameter holes. Nearby, Yamazaki Mazak (hall 20, stand 330) will have nine machines displayed as part of its ‘Building For Your Future’ oering. One of the highlights will be the HCN4000 NEO making its UK debut, a highperformance horizontal machining centre with high productivity, accuracy and environmental performance. Alongside will be a second NEO machine, the VARIAXIS i-800 NEO, a 5-axis machining centre for fully automatic operation over extended periods. With its high rigidity construction and equipped with a 10,000rpm spindle as standard, machine users will be investing in outstanding accuracy and productivity. The VARIAXIS is being exhibited with the Multi-Pallet Pool (MPP), a multiple pallet stocker system oering ¡exible storage for 6, 12 or 18 pallets, 500mm in size. The nal UK debut will be the new MAZATROL DX which extends the functionality of Mazak’s PCbased SmoothCAM AI soware. MAZATROL DX provides customers with valuable new capability to further optimise production with rapid and automatic quotations, automated part programming, virtual machine simulation, and machine process analysis and optimisation. Our next exhibitor is Starrag (hall 18, stand 320) who will present a host of new technologies at the show. From the Bumotec product range, Starrag will present its latest turn/mill product lines. The new Bumotec 191neo is a complete machining solution that enables manufacturers to produce parts from bars or blanks; and with new generation linear motors, seven axes and three spindles with ve simultaneous axes and up to 90 tools. Designed for stable production with minimum operator intervention, the new 191neo incorporates a new MMI touchscreen interface with a Windowsbased PC and a host of additional features and automation solutions. Also new to the Starrag stable is the Heckert H Compact Series, twin pallet horizontal machining centre. This CNC machine delivers the bene ts of a horizontal con guration with a compact footprint. WFL Millturn Technologies UK (hall 20, stand 351) will present a range of high-end technologies at MACH. The new business division set up in collaboration with Kyal Machine Tools will focus on the latest applications from the dierent industries WFL serves as well as soware solutions speci cally geared towards process optimisation, safety and e©ciency. The UK has always been a very important market for WFL, especially in the aerospace industry. In terms of productivity bene ts, the main advantage from using WFL’s machine tools is a reduction in the number of dierent machines required to produce a part. This reduction in complexity has many positive eects on the customer’s production environment. For example, less workpiece clamping means less complexity and simpler production planning. Fintek is the UK agent for OTEC post processing and surface finishing machines and more (left) Mazak’s FSW460V, which incorporates friction stir welding, will be one of the machines making its UK debut at MACH (right) Starrag’s Bumotec 191neo can be seen at its virtual showroom as well as MACH (below) WFL will be focusing on automation with its partner Frai Robotic Solutions (below right) Scan here for more MACH articles
Machines | Automation | Services | Digital | Know-how HELLER Stand No: 19-330 5-axis machining centre F6000 Designed for production – with the 5th axis in the tool for high-performance 5-sided and simultaneous 5-axis machining More information about our aerospace solutions www.heller.biz: HEL-DE-J-24718_AD_UK_AeroManuf_210x146_PRINT.indd 1 23.02.24 09:29 MAPAL.COM | SALES.UK@MAPAL.COM | 01788 574700 OptiMill®-Alu-Wave High-volume machining at over 20 l/min. NeoMill®-Alu-QBig High material removal rates with low cutting forces and high-quality surface finishes. VISIT US ON STAND: 19-332 AEROSPACE MAGAZINE - MAPAL - APRIL ISSUE - MACH.indd 1 16/02/2024 10:29:15 01293 774911 sales@drill-service.co.uk www.drill-service.co.uk THE UK’S LARGEST RANGE OF STANDARD TOOLING AVAILABLE FOR SAME DAY DISPATCH RAPID TURNAROUND ON SPECIAL TOOLING TO KEEP YOUR BUSINESS FLYING Drill Service (Horley) Ltd THE TRUSTED TOOL PARTNER TO THE AVIATION INDUSTRY SINCE 1961
WE LIVE QUALITY TOOLING SLIDING HEAD MACHINING FAST TOOL CHANGES AND THROUGH TOOL COOLANT. AWL SLIDING HEAD RAIL WITH INTEGRATED COOLANT SUPPLY: •Reliable cooling without hose assemblies – thanks to the integrated coolant supply of the sliding head lathe •Flexible – the coolant supply can be completely or partially cut-off •Securely clamped, easy to release – Side mounted wedge clamping screws provides excellent clamping with quick release mechanism AFC TOOL HOLDERS THE REVOLUTION IN FAST TOOL CHANGES: •Simple – only the front part of the holder is removed to change the tool •Precise – repeatability of tool change within +/-0.05mm •Fast – greatly reduced need to reset tools after changeover is reducing downtime © ARNO-2024-03-UK ARNO (UK) Limited | Unit 9, 10 & 11, Sugnall Business Centre Sugnall, Eccleshall Staffordshire | ST21 6NF | Tel +44 01785 850 072 Fax +44 01785 850 076 | sales@arno.de | www.arno-tools.co.uk DOWNLOAD THE WHOLE CATALOGUE NOW AT ARNO.DE See us in hall 20, stand number 579 EDGE ROUNDING Fladder Danmark A/S Tel. +45 75297133 Mail: fladder@fladder.dk www.fladder.com Contact us for a test LS FLEXIBLE DEBURRING
www.aero-mag.com Aerospace Manufacturing April 2024 13 EVENTS: MACH 2024 EXHIBITOR ROUNDUP New centric vice for up to 5-axis machining Easy access from all sides for short tools Fast-acting, self-centring workholding up to 600mm Universal clamp can be adapted quickly toa variety of part geometries and sizes Repeatability to ±0.01mm Upper spindle exerts 52kN clamping force No base distortion or jaw lift on clamping Find out more at www.roemheld.co.uk or call 01670 281400 Roemheld workholding. Driving Innovation through Manufacturing WFL is also focusing on automation for its customers with expert partner Frai Robotic Solutions. Together they support customers at all stages of their automation projects such as initial concept, implementation, commissioning, and maintenance of the automated system. Frai’s gantry robots and robot cells allow for an extensive range of high-quality automation solutions for maximum customer benet. In the same hall, Rösler UK (hall 6, stand 540) will be exhibiting an array of nishing solutions for traditionally produced and additively manufactured parts. Rösler’s RMBC Tumble Belt Blast Machine is essentially for de-sanding, descaling, de-rusting, deburring and creating homogeneous surface nishes, and is ideal for perfect cleaning of dicult-to-reach surface areas, with long uptime, high process stability, and consistent shot blasting results. The R220EC Rotary Vibrator, also on display at MACH, has an inbuilt separation system, designed for processing batch parts, and is perfect for all metal nishing applications from deburring to polishing. Attendees can also witness two AM post-processing technologies: the M1 Basic and the S1 Wet. The M1 Basic promotes superior surface nish of metal or plastic AM parts in a cost-eective and repeatable fashion. The S1 Wet is a versatile wet-blasting solution for cleaning and nishing surfaces on metal and plastic parts and demonstrates the usefulness of shot blasting technologies for AM applications. XYZ Machine Tools (hall 20, stand 140) will have a total of 19 machines on display, including the premiere of the XYZ CT65 LTYS Twin/Sub spindle lathe. The Box Way XYZ CT65 LTYS Twin/ Sub spindle lathe brings the advantages of automated one hit turned and milled components to XYZ’s customers. The machine can turn parts up to 490mm long and bar feed diameters up to 66mm. With twin spindles, live tooling and Y and C axis, this machine can turn and mill complex parts at both ends in one operation, dropping the nished part into its part catcher for hours of unattended machining. For heavy duty machining applications, the XYZ 800 HD includes box slideways and massive ribbed castings for maximum rigidity. Matched with the Siemens 828D control with ShopMill and options for 4th axis rotary tables, this machine has the power and capability to machine the toughest materials. The stand will also feature the ever-popular RMX Bed Mills, KMX Turret Mills and RLX Lathes. Lastly, NCMT (hall 19, stand 130) is celebrating its 60th anniversary this year. It is the sole agent in the UK and Ireland for Japanese-built Makino and Okuma, CNC machine tools. In 2005, Makino-NCMT Grinding Division was established to develop and sell throughout Europe Makino machining platforms for creepfeed VIPER grinding of nickel alloys and since 2015, NCMT has also been the Europe-wide agent for photo-activated adhesive workholding systems manufactured by Blue Photon. At the beginning of 2024 it signed an exclusive distribution agreement in the UK and Ireland with Tritone Technologies, a global leader in additive manufacturing. The Rigid, thermally-stable construction of the Okuma Genos M560V-e vertical machining centre (VMC) protects it from thermal deformation, resulting in high machining performance for an entry-level machine. The 3-axis machine is able to process a variety of materials from titanium to aluminium without sacricing dimensional accuracy, nish quality or productivity. The machine will be equipped with a Cellro X20 robotic system for component load/unload and storage. In a space on the shop¨oor of less than 3.3m², the N25XA horizontal machining centre from Makino is capable of very high-speed machining of components up to 300mm diameter by 270mm high and weighing a maximum of 30kg, including xture. The machine is ideal for fully interpolative, 5-axis machining of complex components made from dicult-to-cut materials like stainless steel, cobalt-chrome and zirconium, as well as titanium- and nickel-based alloys. Typical applications include impellers and compressor blades for the aerospace industry. www.machexhibition.com Rösler specialises in post processing and surface finishing systems (above left) The XYZ 65 LTYS can turn and mill complex parts at both ends in one operation (above) The Okuma Genos M560V-e machine will be equipped with a Cellro X20 robotic system for component load/ unload at the NCMT stand (below left)
14 October 2013 www.aeromag.com April 2024 Aerospace Manufacturing www.aero-mag.com PROGRAMMES: SPACE SECTOR riginally designed to perform ve planned demonstration ights over a 30-day mission, Ingenuity instead logged 72 ights and travelled 14 times farther than expected, ultimately extending its mission to nearly three years. Such overperformance is even more notable from a piece of equipment that cost only $85 million to build and operate in the rst place — a fraction of the $2.4 billion the agency has spent on the Mars 2020 Perseverance mission in total. Ingenuity’s legacy includes a wealth of new data about the challenges of ying in an alien atmosphere, but it also highlights the growing role and value of commercial o -the-shelf (COTS) products in aerospace manufacturing. Like many other satellite and spacecra designers, Ingenuity’s engineers relied on COTS components to reduce its cost and accelerate production. With each of these applications, manufacturers are demonstrating the value of COTS components in space. Those lessons, in turn, are helping component designers here on Earth dial in the right component specications to support missions more cost e ectively. As a result, we’re seeing an acceleration of noteworthy technologies and manufacturing techniques that are reshaping the aerospace industry. Making space for COTS Space-related manufacturing has historically come at a high cost because equipment like satellites were designed to last decades or more. That process included custom-made parts developed for harsh conditions with no possibility of replacement. The James Webb Telescope, for example, operates at temperatures of 22 Kelvin (-250˚C), nearly a million miles from Earth. Any materials likely to release gases under those conditions risk contaminating the telescope’s mirrors and optical components. As a result, traditional space equipment tends to be larger, heavier and takes years to develop. Recently, though, new launch technologies have reduced the cost to send equipment into space, and in response designers and manufacturers have shi ed their focus. For example, the latest generation of low-Earth-orbit (LEO) satellites emphasise lower cost, smaller size and fast assembly, which has designers turning to consumergrade computer hardware and other COTS components to produce satellites in as little as 18 months. As replacement with COTS components is a more economical option, LEO satellite makers can launch multiple satellites to provide backups, and to anticipate shorter equipment lifespans. TE Connectivity (TE) stands out in this dynamic market with a wide-ranging portfolio tailored to the rigors of LEO application. By developing noteworthy technology like the STRADA Whisper backplane connectors, Micro-D and D-subminiature backshells, bre optics, active optical cable assemblies, and 369 connectors to name a few, TE goes beyond product o erings to partnership in innovation. Its engineers In January 2024, NASA’s Ingenuity Mars Helicopter completed its nal ight in the Martian skies a er a hard landing damaged its rotor blades. But that ending shouldn’t overshadow the fact of the helicopter’s remarkable durability. O BEYOND NASA’s Ingenuity Mars Helicopter (above)
www.aero-mag.com Aerospace Manufacturing April 2024 15 champion the charge, working with satellite manufacturers to address their speci c design challenges and capitalising on TE’s time-tested experience in the industry. Aerospace evolution Changing space missions are providing more opportunities to use COTS components. For example, LEO satellites operate much closer to Earth and below the Van Allen radiation belt, which means their components operate in a much less harsh environment than satellites in higher orbits. Those conditions open the door to a broader spectrum of components between consumer grade and bespoke, space-quali ed technology. That spectrum covers everything from existing automotive- or aerospace grade-components to slightly modi ed ‘COTS+’ components that are still more cost eective than traditional spacegrade hardware. Manufacturers are already beginning to incorporate a range of dierent component types into their designs where speci cations warrant. At the same time, latest component suppliers can work closely with these manufacturers to support their design objectives. For example, component manufacturers are playing a key role in helping reduce the overall size and weight of space equipment by miniaturising critical components, particularly those related to power and communications connectivity. The smaller, lighter and more durable these components become, the more room manufacturers have for custom-developed technology or for components that must meet higher speci cations. In addition to helping to reduce costs, the use of COTS components speeds up technology advancement cycles. Engineers can iterate more quickly around a set of standardised components. And shorter mission cycles also oer the potential to upgrade technology at a faster clip than was possible with traditional space equipment manufacturing. Accelerating innovation Space-grade electronic and electromechanical parts that have been radiation hardened and engineered to perform under the harshest conditions will always be necessary, especially in cases like the James Webb Telescope or mission-critical satellites designed to last 25 to 30 years in geosynchronous orbit. As the breadth of aerospace applications has expanded, however, the tolerance requirements for the components needed to ful l a speci c mission have become better de ned. Scan here for more TE articles Matching component speci cations to a speci c mission requires a balance between cost, size, weight and durability. Where COTS components can support a minimum speci cation, their use makes sense. As Ingenuity proved, these components can even exceed expectations. More importantly, COTS components themselves are not a static set of parts. As applications and environments change, component manufacturers can develop new grades of COTS components engineered to meet the evolving speci cations of the vehicles that use them. This isn’t a new phenomenon. In the automotive industry alone, we’ve seen speci cations for COTS components change in areas such as the wiring of electric vehicles. There are also potential applications for the same components across dierent industries. The development of electric vertical take-o and landing (eVTOL) aircra has leveraged COTS components from automotive, military and aerospace technologies to meet the speci cations of short-distance, low-altitude, electricpowered ight. Cross-industry use is possible because many of the components execute similar tasks across applications. Durable connections for transmitting power and data, in particular, tend to be universal. Component manufacturers with deep experience in these areas and a wide range of existing products can help engineers match design speci cations to the most cost-eective alternative currently available. Shaping the future TE’s legacy of mission critical reliability in the space industry dates to the rst US satellite, Explorer 1, launched in 1958. TE remained an important player in the then-nascent industry; for example, its components were used in the rst lunar rovers that were deployed in the early 1970s and continue to be used today. Such layered involvement during this era laid the foundation for TE’s continued contributions to space technology and exploration for more than 75 years. Along the way, we’ve seen how evolving speci cations have helped manufacturers design high-performing equipment faster and more cost eectively. Today, instead of creating bespoke parts from scratch, engineers have a much broader range of options from which to choose the right component at the right level of complexity and robustness for the task they need. As we learn more about the environment in which space equipment operates - and gain greater experience with the performance of COTS in those environments - opportunities for technological advancement continue to grow. And as we’ve seen with Ingenuity Mars helicopter, these innovations will increasingly lead to scienti c breakthroughs that are driving one of the most exciting periods in the history of space exploration. www.te.com/space TE goes beyond product offerings to partnership in innovation (right) TE has made contributions to space technology for more than 75 years (below)
16 October 2013 www.aeromag.com April 2024 Aerospace Manufacturing www.aero-mag.com PROGRAMMES: SPACE SECTOR rowing interest in space travel and the commercialisation of space has led to increased demand for dynamic technologies to tackle the problem of man-made space debris. Among the key challenges facing innovators is the need to nd ways of repairing, refuelling, deorbiting or disposing of satellites to prevent debris-related accidents occurring. Space debris can comprise many di erent things – everything from spent satellites to smaller components or pieces of rockets or other equipment, which travel through space at an average speed of 10km per second. This debris is a collision hazard, which could cause damage to existing satellites and spacecra. The problem has been exacerbated by recent advances in commercial space exploration, driven by private sector investment and falling launch costs, which have led to the release of greatly more unwanted debris in the Earth’s upper atmosphere. In 2019, SpaceX launched Starlink, the world’s largest constellation of satellites in low-Earth orbit, delivering high-speed broadband internet. Initially, almost 12,000 satellites are planned for deployment, but this could be extended to 42,000. It is estimated that by 2030, the global space economy could reach a value of US$1 trillion; with a projected 60,000 satellites active in near-earth orbit in the same year. Space debris has attracted signicant attention from the space industry. In 2022, The European Space Agency (ESA) set out its ambitious Zero Debris plan to eliminate space debris from Earth and Lunar orbits by the end of the decade. In addition, the ESA’s Zero Debris Charter has challenged the industry to nd pioneering methods to dispose of inactive satellites. In the US, NASA is funding two research projects targeting commercial debris mitigation. Private companies are also sharing in the responsibility to clean up space. For example, prior to rocket launches, space companies make plans to deorbit or dispose of satellites to mitigate the risk of equipment turning into debris. To achieve this, they may need to ensure on board propulsion systems function beyond the operational life of the satellite, so that the satellite may deorbit safely. Greater collaboration in the global space industry will be vital to solve the problem of space debris. By sharing intelligence, such as the whereabouts of satellites and mission trajectories, it is possible to improve trac management and reduce the risk of collisions. In orbit innovations To date, much of the emerging technological innovation has focused on refuelling satellites and servicing propulsion units. MacDonald, Dettwiler and Associates (MDA) owns a patent in the US for a dedicated refuelling satellite featuring a robotic arm. Tools can be xed to the arm’s end e ector, to open and close a fuel valve. It is then possible to attach a uid line to a uid valve whilst the satellite is in service. This refuelling satellite can be launched from Earth or from a spacecra or space station and it can also be operated remotely. Astroscale, a Japanese company specialising in orbital debris removal, owns an international patent application for a docking structure In this article, Christopher Range, a partner and patent attorney at European intellectual property (IP) rm Withers & Rogers and leader of its space sector group, discusses the development of innovations to tackle the increasingly dicult problem of space debris. G TAKING OUT THE INTERSTELLAR Space debris can include spent satellites to smaller components such redundant rocket parts (above) Trash Technologies such as robotic arms can be used to service and recover satellites in space (right) Christopher Range, European and UK Chartered patent attorney at Withers & Rogers LLP (below)
www.aero-mag.com Aerospace Manufacturing April 2024 17 that attaches to a satellite using a magnetic plate. The structure allows out-of-service satellites to be captured by another spacecra for repair work or refuelling whilst in orbit. The use of a magnetic plate reduces the need for adhesives to secure the plate to the housing and limits the impact of extreme thermal cycles on the structure’s components. A further innovation in this area is an international patent application owned by Orbit Fab, which describes systems and methods for transferring materials between two space vehicles. In one method, fuel and other materials such as water, coolant and waste, are transferred through a coupling mechanism attached to a representative system. In another method, a service valve is connected to a coupling portion. The innovation is specically designed for refuelling satellites and other spacecra that have been launched into orbit with a limited amount of fuel on board. Another space debris advance has been developed by Airbus. It has patented a magnetic damping device, known as the Detumbler, that attaches Scan here for more Withers & Rogers articles to a satellite. If the satellite begins a tumbling motion in orbit, a central motor inside the device moves too, inducing loops of electrical current (eddy currents) that help to control the satellite’s movement. This technology could also help to remove dead satellites from space, as it is easier to capture moving equipment. Attracting investment These technologies demonstrate the feasibility of both satellite disposal and refuelling technologies, which involve integrating new docking and fuelling mechanisms with existing spacecra xings. However, incompatibility is still a barrier. Fuel caps designed on satellites a decade ago will require matching propellant transfer systems to enable integration. This could make it more challenging to obtain patent protection, since innovators are not working in a commercial vacuum in this respect. Due to the fast pace of technological innovation in this area, newcomers face intense competition, which again could make it more challenging to secure patent protection. It’s worth persevering however and seeking advice about where the best opportunities lie. Once granted, patents can be a useful tool for attracting the attention of investors and potential collaborators, leading to the real-world application of their invention. IP advice Withers & Rogers provides expert advice on the protection and enforcement of IP rights particularly for inventions, designs and trademarks. Its patent and trademark attorneys come with a depth of specialist understanding and pride themselves on helping businesses to commercialise their IP. The company has four oces in the UK (London, Bristol, Warwick and Sheeld) and two further oces in Paris and Munich and its client portfolio stretches across the Americas, the Far East and Australia as well as mainland Europe. Withers & Rogers has a large, technology-diverse client base ranging from major corporations and multinationals to small and medium-sized enterprises and universities. www.withersrogers.com Space debris is likely to increase, especially with the introduction of numerous clusters of small communication satellites (above)
18 October 2013 www.aeromag.com April 2024 Aerospace Manufacturing www.aero-mag.com TECHNOLOGY FEATURE: LANDING GEAR he aerospace industry has long depended on gundrilling and deep hole drilling to manufacture many critical components used in commercial and military aircraft. Deep hole drilling is used for landing gear, cylinders, actuators, piston rods, fittings, shafts, pins and even fasteners. Long, deep holes in parts made from exotic materials are common, and many of these parts have challenging features such as thin wall sections, stepped bores, internal contours and blended transitions. Business change is based on customer demands, and the aerospace industry is experiencing a host of changes related to growth in many global regions that are ying more. And more is expected from suppliers, including greater fuel economy, passenger comfort and the neverending quest for safety, all of which drive engineering and design. As a result, short- ight regional aircra and long-haul aircra are evolving to meet the challenges. But what does this mean for deep hole drilling? Tooling advancements The fundamentals of gundrilling and boring have not changed much over the years. The tools have offcentre tips to create forces against guide pads. This, in turn, helps generate precise holes and ensures straightness and accuracy while providing good surface finishes, roundness and consistency - making deep hole drilling a value-added process. The cutting tool design execution, however, has changed to keep pace with advances in modern metalcutting. Indexable tools, for instance, have been in use for a long time. Over the years, indexable tooling has advanced in terms of carbide grades, coatings, edge geometry, and improved head design to boost the strength and accuracy of the insert seat and clamp. These improvements have allowed smaller, deeper holes to be drilled with indexable tools for better accuracy over previous generation tools. Indexable tools are particularly desirable when special forms are required in the workpiece and multiple hits for each hole are required to create the finished profile. Often referred to as bottle boring, internal contouring with a CNC-controlled axis is becoming mainstream. While the process used to be exclusive for large OEMs with the budget and product line to justify the startup investment, Unisig now offers standard machine configurations, tooling and application support that make it accessible to all manufacturers - and even job shops - that want to grow their aerospace business. Along with tooling advancements, tool presetting is also becoming a necessity when approaching di cultto-manufacture components. The head setup and form measurement are much more controlled when using a laser pre-setter or high-resolution camera to eke out the last few tenths or microns Unisig CEO, Anthony Fettig looks at how the aerospace industry is helping to drive change in deep hole drilling techniques. T A DEEP HOLE DRILL Internal contouring with a CNC-controlled axis is becoming mainstream (above)
from a process. RFID automates communication with the gundrilling or BTA drilling machine CNCs, and reduces the risk of human error. Machine advancements Deep hole drilling machines are becoming smarter, which is critical when the bores produced are dicult to measure or operators are unable to see what is happening at the cutting tool to make adjustments. Accurate, real-time process feedback from the spindle and servo loads, as well as feedback on vibration, temperature, coolant ow and pressure, are necessary to establish a reliable manufacturing plan for aerospace components. Data collection and connected machines provide information that can then be used for analysis and process improvements. The materials selected for aerospace parts are o en exotic and dicult to machine - stainless steels, nickel alloys, titanium and proprietary high-strength alloys are common. Deep hole drilling machines must be engineered to handle these materials and the future materials developed for extreme applications. The motion controllers on the machine - motors, drives, feedback devices and highspeed processors - must maintain exact position and velocity control even when the material and tools are pushing the limits. Automation is another advancement in aerospace machine technology, with every machine, process and application begging the Scan here for more Unisig articles UNISIG machines, engineered and manufactured in the USA Machines • Tools • Automation UNISIG TAKES DEEP HOLE MACHINING FOR AEROSPACE FURTHER Take your aerospace manufacturing further - learn more at UNISIG.com Gundrilling and BTA deep hole machining systems, designed for the complexity of aerospace components Machine complex contours in deep bores, and achieve close tolerances that are impossible with your standard CNC machines. UNISIG machines are designed specifically for the challenging profiles and materials of landing gear, shafts, actuators, and other critical aerospace components. question: Can we automate all or part of this? Automation o en starts by creating a reliable machining process through machine monitoring and adapting, then applying in-machine automation and moving to external part handling robotics. As the aerospace industry changes, so too must the tooling and machines used for generating deep holes in parts. Whether gundrilling or BTA drilling, today’s advanced tooling provides aerospace manufacturers with muchneeded accuracy, while innovative deep hole drilling machines allow for process optimisation through critical data collection and automation. The aerospace industry has strong growth potential, particularly around deep hole drilling. CNC machining centres and multi-tasking machines are o en used to drill deep holes, but some of our most successful projects have involved introducing a gundrilling or deep hole drilling machine to complement the machining centres, unloading long cycle times and eliminating problems from a manufacturing process. www.unisig.de The aerospace industry relies on gundrilling to manufacture critical components (above)
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