technology in action
parts in large runs, allowing them to dial in their production assets once and they’re done. “Aerospace doesn’t have that luxury,” Gibson said. “Our short-run pro- cesses have to be perfect from the start, and frequently changed over to a new part, and then back to another part—all while creat- ing consistent product that’s subject to countless variables measured in tenths of thousands. If the operation can’t handle this constant changeover, you’ll be chasing your tail.” Gibson went on to say that
AeroCision‘s secret to success has always been its people, culture and systems. Its invest- ments in ERP-based produc- tion and quality systems, premium tooling, lean strategies and quality initia- tives enable the company to meet its daily goals of 100% quality and delivery. Gibson, along with his
partner, began to manage AeroCision in 2008. “We both came from outside the industry and brought best practices into the aerospace sector,” he said. “We rebooted the business in our customer-focused image. We are pro-employee, pro- supplier and pro-systems, which translates into very happy customers.” AeroCision’s products include seal assemblies and rings for both the hot and cold sections of turbine engines. The shop machines complex rings up to 34” (864 mm) in diameter and other components from nickel-based alloys and exotic materials including titanium and stainless-steel alloys. Opera- tions are about 60/40 turning/milling and include grinding, EDM and part fi nishing. The company’s quality and production planning systems run on an advanced ERP backbone, and AeroCision recently invested in new CAM software as well a new fi ve-axis mill/ turn center. “We are utilizing as much new technology as possible and getting as much help from tooling and machine tool companies as we can,” Gibson said.
Advanced Toolholding
One example of tooling technology employed by AeroCi- sion to boost component output and quality is the Rego-Fix
powRgrip toolholding system. powRgrip toolholders utilize a special shallow-tapered collet pressed into a holder with a matching taper. Taper accuracy meets AT3 standards and Total Indicated Runout (TIR) is less than 0.0001" (3 μm). The holders provide high-vibra- tion damping and offer length adjust- ment repeatability of less than 10 μm. Either a hydraulic hand pump or an automatic tabletop hydraulic press is used to insert the collets into the holders at clamping forces that are equal to or higher than shrink-fi t holders. Clamping occurs in less than 10 seconds, and because no heat is involved, tools can be used im- mediately after a tool change. AeroCision Engineering Manager Josh Goss said the company began to investigate advanced toolhold- ing technologies when problems arose with end mills pulling out of standard holders and tool- ing exhibiting extreme runout. Dean Spencer from Pioneer Tools Supply, now a divi- sion of Blackhawk Industrial,
Rego-Fix powRgrip toolholding system
was instrumental in introducing the powRgrip System to the AeroCision team. Based on past customer experiences with the equipment, Spencer knew powRgrip would be a good corrective action to this ongoing problem and would reduce cutting tool usage.
Rego-Fix, in conjunction with Pioneer Tools Supply, pro- vided a manual hydraulic mounting unit and a few holders for the powRgrip system and “we noticed the improved tool life instantly,” Goss said. “Average tool life gain is probably 30 to 40 percent. It depends on the application, but in some cases tool life doubles.” Tool life improvements were greatest when using multi-fl ute end mills, a result of the system’s minimal runout. The tool life improvements prompted the shop to try more
aggressive machining parameters. Increased depths of cut permitted average machining time reductions of 10–15% and sometimes up to 20 and 25%. Goss noted the slim, rigid design of the powRgrip holder makes it a good choice when clearance is limited and in long-reach situations. Goss said the shop adjusts parameters to favor shorter cycle times or reduced tooling costs as desired.
96 — Aerospace & Defense Manufacturing 2015
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