Large Complex Part Machining of Tough Alloys

This advanced machine tool uses a high-torque spindle to deliver the stiffness and vibration damping needed for heavy, chatter-free cuts on titanium, Inconel, hardened Carpenter stainless steel and other hard-to-cut alloys used in the aerospace industry.

High-torque cutting performance with hard aerospace alloys produced an order for four large-part HMC 1600s from MAG IAS, LLC (Hebron, KY) to modernize the track-and-beam line at Boeing’s Portland center for complex machining. Equipped with the new T-Rex high-torque spindle, the HMC 1600 performed spectacularly in a cutting test highlighting its 2600 Nm (1918 ft-lb) torque and 42.3 kN (9,500 lb) cutting thrust.

Combined with a chassis of ductile and cast-iron components, the T-Rex-equipped HMC 1600 delivers the stiffness and vibration damping needed for heavy, chatter-free cuts on titanium 5553, Inconel and Carpenter 465 commonly used by Boeing. Phase one for modernizing the track-and-beam line starts with the installation of two MAG 4-axis and two 5-axis machines to replace existing systems and produce more parts with higher accuracy, in greater variety, with less time and cost to meet demand for Next-Generation 737 aircraft.

The T-Rex-equipped HMC 1600 highlights stiffness, power, agility and accuracy when cutting Carpenter 465 stainless steel hardened to 50-52 Rc. The T-Rex spindle delivers triple the metal removal rates over current machining technology for a new level of performance and efficiency.

The modular HMC Series is engineered for high-precision, high-productivity machining of large hard-metal components for aerospace, power generation, pump, valve, and off-road equipment. Designed for extreme application flexibility, the machine offers maximum 3000 mm (118 in) work-zone swing, and 14,000 kg (30,800 lb) pallet load capacity. Major machine components including the X-bed, Z-bed and column are cast ductile iron, with pallets up to 1600 x 2000 mm, headstock and rotary table housings of gray cast iron.