Advanced Precision Machining of Complex Aerospace Components

GF Machining Solutions LLC (Lincolnshire, IL) acquired Liechti Engineering AG (Langnau/BE, Switzerland) to expand their presence in the aerospace sector. Liechti is a specialist in 5-axis milling machines designed to produce blades and blisks for aircraft engines out of titanium, Inconel, titanium aluminide and high-alloy steels, and their go-Mill 350 is a dedicated 5-axis milling system that performs roughing and finishing of complex part shapes found in turbines and cell components for avionics. The go-Mill 350 features a high acceleration 20,000 rpm spindle with an integrated vector control for both efficient low speed roughing as well as finishing at high speeds and feeds. The machine’s combination of torque and rigidity enable it to generate flawless surface finishes, especially around the critical zones of leading and trailing edges on turbine blades and blisks.

To program such challenging components for single-setup processing, the go-Mill 350 is equipped with specialized Turbosoft plus CAM software that makes the machine a complete turnkey system. This interactive, graphic-oriented and parametric software enables easy and efficient modeling and programming of turbine blades and blisks. GF Machining Solutions also offers their Mikron MILL P 800 U ST (Simultaneous Turning) machine that combines both milling and turning operations and was developed with its gantry-type concept as a direct response to the needs of shops serving the aerospace industry and other applications. The MILL P 800 U ST achieves perfect workpiece roundness, superior surface quality and high material removal rates to provide incredible value. Being able to fully machine components on a single machine also eliminates transfer-related part errors and the occurrence of stacked tolerances to further boost finished part quality.

The system is capable of 4-axis simultaneous turning that is especially beneficial when cutting tools must be positioned at 90 deg angles to workpiece surfaces to avoid tool shape errors. For milling, the machine incorporates a 20,000 rpm HSK T63 Step Tec HPC190 spindle, one of the industry’s fastest for a milling and turning machine of this size. Highly efficient, the compact MILL P 800 U ST provides 31.5 in (800 mm) of X-axis travel, an 800 rpm C-axis rotation speed and a maximum table load of 1,763 lb (800 kg). Additionally, water-cooled high torque motors on the A-axis and C-axis ensure accuracy and stability, while a 0.3 second clamp time in any position further contributes to overall part-processing speed.

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The machine can cut aluminum parts more than 50 percent faster than conventional processing. Its small 137 in x 118 in footprint easily integrates into existing operations, replacing two machines in the process. With the gantry concept, workpieces on the 31.5 in x 31.5 in table are fully accessible without rotating the table. This eliminates errors related to table rotation and helps reduce the need for hand polishing part surfaces. The tool changer for the machine is also located so as to avoid having to move the table during tool changes as well. The Machine and Spindle Protection (MSP) system adds security to the machining process. It protects the machine and spindle in the event of crashes during setup and/or machining. And, as the only system to offer such protection in all directions/axes, MSP eliminates not only spindle damage, but also misaligned machine geometry as well as downtime and costs related to unexpected crashes. The MILL P 800 U ST is automation-ready and equipped with pallet changers for 2 pallets, 7 pallets, 9 pallets or 12 pallets. It also easily integrates into existing automation systems, such as System 3R automation.System 3R automation

GF Machining Solutions also offers their FORM 200 die-sinking EDM that brings production-boosting features to applications that require the use of many electrodes for machining molds and aerospace parts, as well as automotive and energy applications. The FORM 200 is equipped with an Intelligent Speed Power Generator (ISPG), a powerful digital generator that uses several patented technologies to reduce electrode wear and generate high levels of surface quality, material removal and accuracy of form. One such technology is the revolutionary iQ technology that dramatically reduces, and in some cases completely eliminates, electrode wear with graphite and copper electrodes. This improves productivity by reducing setup time and increasing machine utilization rates. It also lowers costs by decreasing the number of electrodes required.

Standard on the FORM 200 is iGAP, an embedded auto-adaptive system that alters the discharge current and pulse duration in real-time according to machine conditions. This system enables the machine to deliver faster cutting speeds and reduces electrode wear, especially lateral wear, resulting in as much as 50 percent shorter machining times for completed parts. To help manufacturers achieve more homogenous results and reduce the number of electrodes required, FORM 200 employs Wear Partitioning, a function that effectively manages electrode wear when machining multiple cavities with the same shape and depth. By spreading electrode wear evenly between all the cavities being machined, Wear Partitioning results in the same surface finish and dimensional tolerance requirements in all cavities machined throughout the process. FORM 200’s powerful AC FORM HMI control system is easy to operate and streamlines mold making techniques. It maximizes production time through flexible job organization and interactive graphical assistance to make programming faster.

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The machine also increases efficiency of mold production, which frequently requires multiple electrodes, by accommodating integrated tool changers in a variety of configurations including linear, rotary or even an external robot. It houses up to five plates with 16 positions, 30 positions, or 32 positions per plate for a maximum of 160 electrodes. Additionally, a double gripper reduces unnecessary movements to speed up the loading process. With a compact footprint of 74.8 in x 66.53 in x 94.4 in, the FORM 200 optimizes shop floor space and provides easy access to all functionalities. It has an X-axis travel of 13.78 in, Y-axis travel of 9.84 in, and Z-axis travel of 11.81 in, making it ideal for production of small and large helical gears, turbine blades and large electrodes.

GF Machining Solutions LLC, 560 Bond Street, Lincolnshire, IL 60069-4224, 847-913-5300, Fax: 847-913-5340, www.gfms.com/us.