Clamp once – machine complete

WFL Millturn Technologies reveals why its mantra of ‘clamp once – machine complete’ is proving so popular with aerospace customers when it comes to the innovative part production of landing gear components.

Complete machining is subject to different demands today, which is why WFL strives to integrate a wide range of technologies, measuring tasks and finish machining operations into its MILLTURN complete machining centres to suit the aerospace sector’s needs.

However, WFL focuses on more than just the machining operation itself – the company chooses to cover the entire process. This means defining the machining process, workpiece programming, simulation, production and finally, support throughout the entire service life of a machine.

WFL’s MILLTURNs are used mainly for parts like landing gear components, different types of turbine shafts, fuel pump housings and other components. The company’s objective is to always exceed the customers’ expectations in terms of quality, reliability and efficiency.

Reducing the amount of clamping decreases the risk of clamping errors and consequently improves the process quality. Automatic measuring solutions ensure the highest possible process quality. These measurement readings can be recorded and monitored in WFL’s Process Monitoring advanced software – WFL iControl, which helps the traceability required for such components.

Time to shine

WFL says the MILLTURNs really shine when machining large landing gear components. The extremely ridged design of the machine centring around a 60° slant bed enables the customer to perform deep ID machining operations to avoid another clamping in a dedicated machine, resulting in better quality, less floor space and reduced operation costs.

In terms of productivity benefits customers enjoy from the implementation of WFL’s machine tools, the main advantage is the reduction in the amounts of different machines required to produce a part. This reduction in complexity has many positive effects on the customers production environment. For example, less workpiece clamping, results in less complexity and simpler production planning. Furthermore, a large tool magazine helps in changeover times since all tools can be kept in the machine for different parts or different clamping. Lately highest rigidity for efficient machining of exotic alloys and the compact design of the machine, as well as the latest in-machine cutting-edge metrology in conjunction with process control software round off the total package.

Integrating different machining and inspection steps into one MILLTURN results in significantly reduced intermediary stock and waiting time. Machining time, storage costs and component lead-time are reduced. WFL provides turnkey solutions that include production strategy, tool selection and programming in addition to the machine. WFL’s range of technology expertise includes ID machining, bottle boring operations and facing head operations for eccentric turning. All benefits of complete machining for aerospace work are exploited, setting new standards in value and precision.

WFL’s latest additions for the manufacturing of large parts include the M175 for up to 1,700mm swing and heavy workpieces and the M175LS (Large Swing) for up to 2,000mm swing for medium workpiece weights. The M175LS is a particularly interesting machine for the aerospace industry since it can swing many large landing gear components, as well as large discs.

At the other end of the MILLTURN spectrum is the M20. This machine comprises two single tool carriers with automatic tool change, as well as fully integrated automatic loading and unloading of parts.

With the acquisition of FRAI Robotics, WFL has become a system supplier offering its customers complete automatic production systems. Therefore, a lot of R&D effort goes into Closed Door Machining and system integration. Different technical disciplines must work well together to keep machine doors shut at all times and keep spindles running. WFL says that what sets it apart is a drive for excellence and an understanding that the company is spearheading complete machining.

The latest product is the FRAI mobileCELL, a hybrid solution which is said to impress customers with its combination of wide-ranging functions and advantages. It’s a generously-sized automated guided vehicle (AGV) with a robot cell design. It has everything you need, including the robot, workpiece and tool gripper, along with buffer positions for workpieces and tools, and the necessary control and safety technology. The machine is freely accessible. The AGV collects the required tools and workpieces in the warehouse, it then travels to the front of the machine, locks itself in place on the floor and exchanges parts and/or tools. The vehicle then moves away again and receives the travel instructions for the next machine. The space in front of the machine it has just loaded becomes clear again.

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