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Shop Solutions


equipped with advanced programming software, special tool- ing and custom fi xturing will slash machining cycle times by as much as 50%.


The shop produces over 500 different part number blades from a basic group of six different sized large-envelope forgings. The largest size aircraft blade measures 5' (1.5-m) long and a special wind tunnel blade is 7' (2.1-m) long. Blades receive some rough machining on the ODs and IDs of their shanks—the interface to the hub of the propeller assembly. Then the airfoil contours get machined. Depending on size, complete machining time can range from 15 minutes up to an hour (for larger sizes). In machining operations, blades rotate around via the machine’s synchro- nized C-axis motion.


Balance among each blade of a pro- peller assembly is extremely critical, which is why Hartzell manufactures blades in sets. So for three-blade assemblies, for example, the shop would make the blades in groups of 3, 6, 9 and 12. For tracking purposes, blades are serialized. “Even though our manufacturing processes are extremely repeatable, there are several stages in blade set manufacturing when we will check balance,” said Barhorst. “And when they are complete, we subject them to a digital balancing operation, then again when they are together as a complete propeller assembly.” However, Barhorst said that with the highly accurate Mazak machine tool technology, the shop eliminates the necessity of machining serialized sets all at one time. Instead for instance, it gains the production fl exibility to switch from machining blades for a three-blade propeller assembly to those for a four- blade assembly and back again—all on the same machine and without affecting blade integrity, accuracy, or balance.


“What this means is that a blade we produce today will be the same as a blade we produce in the future, but minus the variation we might have had in the past,” said Barhorst.


With a German ZF Gearbox that produces 2700 Foot Pounds of Torque and a Quill that extends 31", the spindle of the SMTCL PBC130 is built for aggressive machining.


Engineered in Germany, SMTCL’s PBC130 Horizontal Boring & Milling Machine delivers incredible performance and value. Equipped with Heidenhain scales and a FANUC 31i CNC control, the PBC130 features 118” x 63” x 63” travels (XYZ) and can accommodate parts up to 22,000 lbs. PBC130 machines are in stock in the US and available for immediate delivery.


SMTCL offers over 300 different machine models, including ten models of our PBC Horizontal Boring & Milling Machines. Our California-based team and network of local distributors provide the applications engineering and service support that you demand. Call or visit our website to see how SMTCL can deliver for you.


www.smtcl-americas.com 626-667-1192


March 2014 | ManufacturingEngineeringMedia.com 49


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