by Brian J. Papke, President
Mazak Corporation, Florence, Kentucky
Multi-tasking machining solutions are on the rise in many manufacturing industries because of their versatility and productivity improvements compared to traditional manufacturing approaches. Traditional for aerospace manufacturing has long meant bridge-type or C-frame gantry-style five-axis machining centers for large airframe components and a combination of milling and turning centers for engine and other components.
Yet product development and manufacturing issues are rapidly changing for aerospace manufacturers. From the nose cone to the tail, parts for engines and airframes alike are increasing in complexity. Exotic, expensive and hard-to-machine materials including titanium, Inconel, and composites are in high demand, both for original equipment and aftermarket parts. Sources are rare, however, and lead times are long. Increasing part complexity means increased programming time and longer processing times. Cost pressures and competition for meeting growing demand in an active aerospace market around the world will only get tougher.
Improving throughput will be the key. Five-axis machining in the aerospace industry is not new, but today there are many more different forms to choose from. Vertical machining centers with rotating tables, vertical or horizontal machining centers with trunnion tables, and vertical machining centers with nutating heads are among the offerings. It is only a small step from these types of machines to realize the benefits of full-blown five-axis multi-tasking machine tools for the aerospace industry.
Each aerospace application is unique, and the multi-tasking approach excels with so many different ways to add functions, eliminate multiple machines and fixturing and accelerate throughput. Orders-of-magnitude improvements become possible. Customers have reported machining times for 7,400-lb titanium forgings that used to take 45 days are now being completed in three on multi-tasking machines. A manufacturer of main pistons and cylinders switching to Mazak’s Integrex e-650H saw setups from raw material to post-machining drop from six to two; machining hours go down from 50 to 13, and hand-bench operations from 22 hours to 2. What originally took six weeks is now accomplished in less than two shifts.
Add process automation and the benefits of an integrated multi-tasking solution increase. For example, aerospace manufacturers can configure large three-axis bridge-type machines with five-axis gantry-type vertical machining centers in an overall Palletech Manufacturing Cell. This puts pallet stocking, loading and unloading, washing stations, and all movement between machines under a single system controller. High-horsepower, high-speed machining combines with automation to address skilled-labor shortages and reduce costs while efficiently delivering high-quality components.
Mazak is actively listening so we can deliver the resources the aerospace industry demands. Our Technology Center network continues to expand to put new process-development thinking and hands-on applications in front of aerospace manufacturers from engine developers in New England to airframe OEMs on the West Coast. Often, these high-speed and multi-tasking machining solutions can work with Palletech material-handling automation to further increase spindle uptime while providing unattended machining. Networking and system integration, particularly though more powerful CNC controls such as the sixth-generation Mazatrol Matrix, can contribute to better efficiencies. Intelligent machine functions such as active vibration control, intelligent thermal shield, and toolpath simulations at the machine are all functions of more powerful controls. And Mazak Technology Centers embrace process improvements from tooling, workholding, automation, software, and other leading technology partners to craft the most efficient solution possible.
Dramatic throughput reductions can increase part-flow efficiency throughout entire aerospace facilities. Better-performing facilities result in better-performing supply chains, and an entire industry becomes stronger. Older machine tools and systems will not cut it in this marketplace; neither will old process thinking. New multi-tasking machining solutions are the right answer for aerospace in rising markets and perhaps even more important in declining ones.
